Dodge - Caravan - Workshop Manual - 2002 - 2002

EMISSIONS CONTROL RS 25 - 1 EMISSIONS CONTROL TABLE OF CONTENTS page EMISSIONS CONTROL DESCRIPTION DESCRIPTION - VEHICLE EMISSION CONTROL INFORMATION LABEL . . . . . . . . DESCRIPTION - TRIP DEFINITION . . . . . . . DESCRIPTION - MONITORED COMPONENT OPERATION - NON-MONITORED CIRCUITS DESCRIPTION - MONITORED SYSTEMS . . ..1 ..1 .1 ..5 ..6 EMISSIONS CONTROL DESCRIPTION DESCRIPTION - VEHICLE EMISSION CONTROL INFORMATION LABEL All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label. DESCRIPTION - TRIP DEFINITION A “Trip” means vehicle operation (following an engine-off period) of duration and driving mode such that all components and systems are monitored at least once by the diagnostic system. The monitors must successfully pass before the PCM can verify that a previously malfunctioning component is meeting the normal operating conditions of that component. For misfire or fuel system malfunction, the MIL may be extinguished if the fault does not recur when monitored during three subsequent sequential driving cycles in which conditions are similar to those under which the malfunction was first determined. Anytime the MIL is illuminated, a DTC is stored. The DTC can self erase only after the MIL has been extinguished. Once the MIL is extinguished, the PCM must pass the diagnostic test for the most recent DTC for 40 warm-up cycles (80 warm-up cycles for the Fuel System Monitor and the Misfire Monitor). A warm-up cycle can best be described by the following: • The engine must be running page DESCRIPTION - HIGH AND LOW LIMITS . . . . 9 OPERATION OPERATION - SYSTEM . . . . . . . . . . . . . . . . . . 9 DRB IIIT STATE DISPLAY TEST MODE . . . . . 10 EVAPORATIVE EMISSIONS . . . . . . . . . . . . . . . . 11 EXHAUST GAS RECIRCULATION . . . . . . . . . . . 20 ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . 24 • A rise of 40°F in engine temperature must occur from the time when the engine was started • Engine coolant temperature must crossover 160°F • A “driving cycle” that consists of engine start up and engine shut off. Once the above conditions occur, the PCM is considered to have passed a warm-up cycle. Due to the conditions required to extinguish the MIL and erase the DTC, it is most important that after a repair has been made, all DTC’s be erased and the repair verified by running 1–good trip. DESCRIPTION - MONITORED COMPONENT There are several components that will affect vehicle emissions if they malfunction. If one of these components malfunctions the Malfunction Indicator Lamp (Check Engine) will illuminate. Some of the component monitors are checking for proper operation of the part. Electrically operated components now have input (rationality) and output (functionality) checks. Previously, a component like the Throttle Position sensor (TPS) was checked by the PCM for an open or shorted circuit. If one of these conditions occurred, a DTC was set. Now there is a check to ensure that the component is working. This is done by watching for a TPS indication of a greater or lesser throttle opening than MAP and engine rpm indicate. In the case of the TPS, if engine vacuum is low and engine rpm is 1600 or greater and the TPS indicates a small throttle opening, a DTC will be set. The same applies to low vacuum and 1600 rpm. Any component that has an associated limp in will set a fault after 1 trip with the malfunction present. Refer to the Diagnostic Trouble Codes Description Charts (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE - DESCRIPTION) and the appropriate Powertrain Diagnostic Procedure Manual for diagnostic procedures. 25 - 2 EMISSIONS CONTROL RS EMISSIONS CONTROL (Continued) The following is a list of the monitored components: • Comprehensive Components • Oxygen Sensor Monitor • Oxygen Sensor Heater Monitor • Catalyst Monitor COMPREHENSIVE COMPONENTS Along with the major monitors, OBD II requires that the diagnostic system monitor any component that could affect emissions levels. In many cases, these components were being tested under OBD I. The OBD I requirements focused mainly on testing emissions-related components for electrical opens and shorts. However, OBD II also requires that inputs from powertrain components to the PCM be tested for rationality, and that outputs to powertrain components from the PCM be tested for functionality. Methods for monitoring the various Comprehensive Component monitoring include: (1) Circuit Continuity • Open • Shorted high • Shorted to ground (2) Rationality or Proper Functioning • Inputs tested for rationality • Outputs tested for functionality NOTE: Comprehensive component monitors are continuous. Therefore, enabling conditions do not apply. Input Rationality—While input signals to the PCM are constantly being monitored for electrical opens and shorts, they are also tested for rationality. This means that the input signal is compared against other inputs and information to see if it makes sense under the current conditions. PCM sensor inputs that are checked for rationality include: • Manifold Absolute Pressure (MAP) Sensor • Oxygen Sensor (O2S) • Engine Coolant Temperature (ECT) Sensor • Camshaft Position (CMP) Sensor • Vehicle Speed Sensor • Crankshaft Position (CKP) Sensor • Intake/inlet Air Temperature (IAT) Sensor • Throttle Position (TPS) Sensor • Ambient/Battery Temperature Sensors • Power Steering Switch • Oxygen Sensor Heater • Engine Controller • Brake Switch • Leak Detection Pump Switch (if equipped) • P/N Switch • Trans Controls Output Functionality—PCM outputs are tested for functionality in addition to testing for opens and shorts. When the PCM provides a voltage to an output component, it can verify that the command was carried out by monitoring specific input signals for expected changes. For example, when the PCM commands the Idle Air Control (IAC) Motor to a specific position under certain operating conditions, it expects to see a specific (target) idle speed (RPM). If it does not, it stores a DTC. PCM outputs monitored for functionality include: • Fuel Injectors • Ignition Coils • Torque Converter Clutch Solenoid • Idle Air Control • Purge Solenoid • EGR Solenoid (if equipped) • LDP Solenoid (if equipped) • Radiator Fan Control • Trans Controls OXYGEN SENSOR (O2S) MONITOR DESCRIPTION—Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperature 300° to 350°C (572° to 662°F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. When there is a large amount of oxygen in the exhaust caused by a lean condition, the sensor produces a low voltage, below 450 mV. When the oxygen content is lower, caused by a rich condition, the sensor produces a higher voltage, above 450mV. The information obtained by the sensor is used to calculate the fuel injector pulse width. The PCM is programmed to maintain the optimum air/fuel ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrous oxide (NOx) from the exhaust. The O2S is also the main sensing element for the EGR (if equipped), Catalyst and Fuel Monitors. The O2S may fail in any or all of the following manners: • Slow response rate (Big Slope) • Reduced output voltage (Half Cycle) • Heater Performance Slow Response Rate (Big Slope)—Response rate is the time required for the sensor to switch from lean to rich signal output once it is exposed to a richer than optimum A/F mixture or vice versa. As the PCM adjusts the air/fuel ratio, the sensor must be able to rapidly detect the change. As the sensor ages, it could take longer to detect the changes in the oxygen content of the exhaust gas. The rate of change that an oxygen sensor experiences is called RS EMISSIONS CONTROL 25 - 3 EMISSIONS CONTROL (Continued) “Big Slope”. The PCM checks the oxygen sensor voltage in increments of a few milliseconds. Reduced Output Voltage (Half Cycle)—The output voltage of the O2S ranges from 0 to 1 volt. A good sensor can easily generate any output voltage in this range as it is exposed to different concentrations of oxygen. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the threshold value. Each time the voltage signal surpasses the threshold, a counter is incremented by one. This is called the Half Cycle Counter. Heater Performance—The heater is tested by a separate monitor. Refer to the Oxygen Sensor Heater Monitor. OPERATION—As the Oxygen Sensor signal switches, the PCM monitors the half cycle and big slope signals from the oxygen sensor. If during the test neither counter reaches a predetermined value, a malfunction is entered and Freeze Frame data is stored. Only one counter reaching its predetermined value is needed for the monitor to pass. The Oxygen Sensor Monitor is a two trip monitor that is tested only once per trip. When the Oxygen Sensor fails the test in two consecutive trips, the MIL is illuminated and a DTC is set. The MIL is extinguished when the Oxygen Sensor monitor passes in three consecutive trips. The DTC is erased from memory after 40 consecutive warm-up cycles without test failure. Enabling Conditions—The following conditions must typically be met for the PCM to run the oxygen sensor monitor: • Battery voltage • Engine temperature • Engine run time • Engine run time at a predetermined speed • Engine run time at a predetermined speed and throttle opening • Transmission in gear and brake depressed (automatic only) • Fuel system in Closed Loop • Long Term Adaptive (within parameters) • Power Steering Switch in low PSI (no load) • Engine at idle • Fuel level above 15% • Ambient air temperature • Barometric pressure • Engine RPM within acceptable range of desired idle Pending Conditions—The Task Manager typically does not run the Oxygen Sensor Monitor if overlapping monitors are running or the MIL is illuminated for any of the following: • Misfire Monitor • Front Oxygen Sensor and Heater Monitor • MAP Sensor • Vehicle Speed Sensor • Engine Coolant Temperature Sensor • Throttle Position Sensor • Engine Controller Self Test Faults • Cam or Crank Sensor • Injector and Coil • Idle Air Control Motor • EVAP Electrical • EGR Solenoid Electrical (if equipped) • Intake/inlet Air Temperature • 5 Volt Feed Conflict—The Task Manager does not run the Oxygen Sensor Monitor if any of the following conditions are present: • A/C ON (A/C clutch cycling temporarily suspends monitor) • Purge flow in progress • Ethanel content learn is takeng place and the ethenal used once flag is set (if equipped) Suspend—The Task Manager suspends maturing a fault for the Oxygen Sensor Monitor if any of the following are present: • Oxygen Sensor Heater Monitor, Priority 1 • Misfire Monitor, Priority 2 OXYGEN SENSOR HEATER MONITOR DESCRIPTION—If there is an oxygen sensor (O2S) DTC as well as a O2S heater DTC, the O2S fault MUST be repaired first. After the O2S fault is repaired, verify that the heater circuit is operating correctly. The voltage readings taken from the O2S are very temperature sensitive. The readings are not accurate below 300°C. Heating of the O2S is done to allow the engine controller to shift to closed loop control as soon as possible. The heating element used to heat the O2S must be tested to ensure that it is heating the sensor properly. The heater element itself is not tested. The sensor output is used to test the heater by isolating the effect of the heater element on the O2S output voltage from the other effects. The resistance is normally between 100 ohms and 4.5 megaohms. When oxygen sensor temperature increases, the resistance in the internal circuit decreases. The PCM sends a 5 volts biased signal through the oxygen sensors to ground this monitoring circuit. As the temperature increases, resistance decreases and the PCM detects a lower voltage at the reference signal. Inversely, as the temperature decreases, the resistance increases and the PCM detects a higher voltage at the reference signal. The O2S circuit is monitored for a drop in voltage. OPERATION—The Oxygen Sensor Heater Monitor begins after the ignition has been turned OFF. 25 - 4 EMISSIONS CONTROL RS EMISSIONS CONTROL (Continued) The PCM sends a 5 volt bias to the oxygen sensor every 1.6 seconds. The PCM keeps it biased for 35 ms each time. As the sensor cools down, the resistance increases and the PCM reads the increase in voltage. Once voltage has increased to a predetermined amount, higher than when the test started, the oxygen sensor is cool enough to test heater operation. When the oxygen sensor is cool enough, the PCM energizes the ASD relay. Voltage to the O2 sensor begins to increase the temperature. As the sensor temperature increases, the internal resistance decreases. The PCM continues biasing the 5 volt signal to the sensor. Each time the signal is biased, the PCM reads a voltage decrease. When the PCM detects a voltage decrease of a predetermined value for several biased pulses, the test passes. The heater elements are tested each time the engine is turned OFF if all the enabling conditions are met. If the monitor fails, the PCM stores a maturing fault and a Freeze Frame is entered. If two consecutive tests fail, a DTC is stored. Because the ignition is OFF, the MIL is illuminated at the beginning of the next key cycle. Enabling Conditions—The following conditions must be met for the PCM to run the oxygen sensor heater test: • Engine run time of at least 3 minutes • Engine run time at a predetermind speed and throttle opening. • Key OFF power down • Battery voltage of at least 10 volts • Sufficient Oxygen Sensor cool down Pending Conditions—There are not conditions or situations that prompt conflict or suspension of testing. The oxygen sensor heater test is not run pending resolution of MIL illumination due to oxygen sensor failure. Suspend—There are no conditions which exist for suspending the Heater Monitor. CATALYST MONITOR To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide. Normal vehicle miles or engine misfire can cause a catalyst to decay. A meltdown of the ceramic core can cause a reduction of the exhaust passage. This can increase vehicle emissions and deteriorate engine performance, driveability and fuel economy. The catalyst monitor uses dual oxygen sensors (O2S’s) to monitor the efficiency of the converter. The dual O2S strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both reduced. By monitoring the oxy- gen storage capacity of a catalyst, its efficiency can be indirectly calculated. The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter. The PCM calculates the A/F mixture from the output of the O2S. A low voltage indicates high oxygen content (lean mixture). A high voltage indicates a low content of oxygen (rich mixture). When the upstream O2S detects a lean condition, there is an abundance of oxygen in the exhaust gas. A functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstream O2S will indicate limited activity in this condition. As the converter loses the ability to store oxygen, the condition can be detected from the behavior of the downstream O2S. When the efficiency drops, no chemical reaction takes place. This means the concentration of oxygen will be the same downstream as upstream. The output voltage of the downstream O2S copies the voltage of the upstream sensor. The only difference is a time lag (seen by the PCM) between the switching of the O2S’s. To monitor the system, the number of lean-to-rich switches of upstream and downstream O2S’s is counted. The ratio of downstream switches to upstream switches is used to determine whether the catalyst is operating properly. An effective catalyst will have fewer downstream switches than it has upstream switches i.e., a ratio closer to zero. For a totally ineffective catalyst, this ratio will be one-toone, indicating that no oxidation occurs in the device. The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over the legal limit, the MIL (check engine lamp) will be illuminated. Monitor Operation—To monitor catalyst efficiency, the PCM expands the rich and lean switch points of the heated oxygen sensor. With extended switch points, the air/fuel mixture runs richer and leaner to overburden the catalytic converter. Once the test is started, the air/fuel mixture runs rich and lean and the O2 switches are counted. A switch is counted when an oxygen sensor signal goes from below the lean threshold to above the rich threshold. The number of Rear O2 sensor switches is divided by the number of Front O2 sensor switches to determine the switching ratio. The test runs for 20 seconds. As catalyst efficiency deteriorated over the life of the vehicle, the switch rate at the downstream sensor approaches that of the upstream sensor. If at any point during the test period the switch ratio reaches a predetermined value, a counter is incremented by one. The monitor RS EMISSIONS CONTROL 25 - 5 EMISSIONS CONTROL (Continued) is enabled to run another test during that trip. When the test fails 6 times, the counter increments to 3, a malfunction is entered, and a Freeze Frame is stored, the code is matured and the MIL is illuminated. If the first test passes, no further testing is conducted during that trip. The MIL is extinguished after three consecutive good trips. The good trip criteria for the catalyst monitor is more stringent than the failure criteria. In order to pass the test and increment one good trip, the downstream sensor switch rate must be less than 45% of the upstream rate. The failure percentages are 59% respectively. Enabling Conditions—The following conditions must typically be met before the PCM runs the catalyst monitor. Specific times for each parameter may be different from engine to engine. • Accumulated drive time • Enable time • Ambient air temperature • Barometric pressure • Catalyst warm-up counter • Engine coolant temperature • Vehicle speed • MAP • RPM • Engine in closed loop • Fuel level Pending Conditions— • Misfire DTC • Front Oxygen Sensor Response • Front Oxygen Sensor Heater Monitor • Front Oxygen Sensor Electrical • Rear Oxygen Sensor Rationality (middle check) • Rear Oxygen Sensor Heater Monitor • Rear Oxygen Sensor Electrical • Fuel System Monitor • All TPS faults • All MAP faults • All ECT sensor faults • Purge flow solenoid functionality • Purge flow solenoid electrical • All PCM self test faults • All CMP and CKP sensor faults • All injector and ignition electrical faults • Idle Air Control (IAC) motor functionality • Vehicle Speed Sensor • Brake switch (auto trans only) • Intake air temperature Conflict—The catalyst monitor does not run if any of the following are conditions are present: • EGR Monitor in progress (if equipped) • Fuel system rich intrusive test in progress • EVAP Monitor in progress • Time since start is less than 60 seconds • Low fuel level-less than 15 % • Low ambient air temperature • Ethanel content learn is takeng place and the ethenal used once flag is set Suspend—The Task Manager does not mature a catalyst fault if any of the following are present: • Oxygen Sensor Monitor, Priority 1 • Oxygen Sensor Heater, Priority 1 • EGR Monitor, Priority 1 (if equipped) • EVAP Monitor, Priority 1 • Fuel System Monitor, Priority 2 • Misfire Monitor, Priority 2 OPERATION - NON-MONITORED CIRCUITS The PCM does not monitor all circuits, systems and conditions that could have malfunctions causing driveability problems. However, problems with these systems may cause the PCM to store diagnostic trouble codes for other systems or components. For example, a fuel pressure problem will not register a fault directly, but could cause a rich/lean condition or misfire. This could cause the PCM to store an oxygen sensor or misfire diagnostic trouble code. The major non-monitored circuits are listed below along with examples of failures modes that do not directly cause the PCM to set a DTC, but for a system that is monitored. FUEL PRESSURE The fuel pressure regulator controls fuel system pressure. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply or return line. However, these could result in a rich or lean condition causing the PCM to store an oxygen sensor, fuel system, or misfire diagnostic trouble code. SECONDARY IGNITION CIRCUIT The PCM cannot detect an inoperative ignition coil, fouled or worn spark plugs, ignition cross firing, or open spark plug cables. The misfire will however, increase the oxygen content in the exhaust, deceiving the PCM in to thinking the fuel system is too lean. Also misfire detection. CYLINDER COMPRESSION The PCM cannot detect uneven, low, or high engine cylinder compression. Low compression lowers O2 content in the exhaust. Leading to fuel system, oxygen sensor, or misfire detection fault. EXHAUST SYSTEM The PCM cannot detect a plugged, restricted or leaking exhaust system. It may set a EGR (if equipped) or Fuel system or O2S fault. 25 - 6 EMISSIONS CONTROL RS EMISSIONS CONTROL (Continued) FUEL INJECTOR MECHANICAL MALFUNCTIONS The PCM cannot determine if a fuel injector is clogged, the needle is sticking or if the wrong injector is installed. However, these could result in a rich or lean condition causing the PCM to store a diagnostic trouble code for either misfire, an oxygen sensor, or the fuel system. EXCESSIVE OIL CONSUMPTION Although the PCM monitors engine exhaust oxygen content when the system is in closed loop, it cannot determine excessive oil consumption. THROTTLE BODY AIR FLOW The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. VACUUM ASSIST The PCM cannot detect leaks or restrictions in the vacuum circuits of vacuum assisted engine control system devices. However, these could cause the PCM to store a MAP sensor diagnostic trouble code and cause a high idle condition. PCM SYSTEM GROUND The PCM cannot determine a poor system ground. However, one or more diagnostic trouble codes may be generated as a result of this condition. The module should be mounted to the body at all times, also during diagnostic. PCM CONNECTOR ENGAGEMENT The PCM may not be able to determine spread or damaged connector pins. However, it might store diagnostic trouble codes as a result of spread connector pins. DESCRIPTION - MONITORED SYSTEMS There are new electronic circuit monitors that check fuel, emission, engine and ignition performance. These monitors use information from various sensor circuits to indicate the overall operation of the fuel, engine, ignition and emission systems and thus the emissions performance of the vehicle. The fuel, engine, ignition and emission systems monitors do not indicate a specific component problem. They do indicate that there is an implied problem within one of the systems and that a specific problem must be diagnosed. If any of these monitors detect a problem affecting vehicle emissions, the Malfunction Indicator (Check Engine) Lamp will be illuminated. These monitors generate Diagnostic Trouble Codes that can be displayed with the a DRBIIIt scan tool. The following is a list of the system monitors: • EGR Monitor (if equipped) • Misfire Monitor • Fuel System Monitor • Oxygen Sensor Monitor • Oxygen Sensor Heater Monitor • Catalyst Monitor • Evaporative System Leak Detection Monitor (if equipped) Following is a description of each system monitor, and its DTC. Refer to the appropriate Powertrain Diagnostics Procedures manual for diagnostic procedures. OXYGEN SENSOR (O2S) MONITOR Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperatures of 300° to 350°C (572° to 662°F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. The PCM is programmed to maintain the optimum air/fuel ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrous oxide (NOx) from the exhaust. The O2S is also the main sensing element for the EGR (if equipped), Catalyst and Fuel Monitors. The O2S may fail in any or all of the following manners: • Slow response rate • Reduced output voltage • Dynamic shift • Shorted or open circuits Response rate is the time required for the sensor to switch from lean to rich once it is exposed to a richer than optimum A/F mixture or vice versa. As the sensor starts malfunctioning, it could take longer to detect the changes in the oxygen content of the exhaust gas. The output voltage of the O2S ranges from 0 to 1 volt. A good sensor can easily generate any output voltage in this range as it is exposed to different concentrations of oxygen. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the threshold value. OXYGEN SENSOR HEATER MONITOR If there is an oxygen sensor (O2S) DTC as well as a O2S heater DTC, the O2S fault MUST be repaired first. After the O2S fault is repaired, verify that the heater circuit is operating correctly. RS EMISSIONS CONTROL 25 - 7 EMISSIONS CONTROL (Continued) Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperatures of 300° to 350°C (572 ° to 662°F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. This maintains a 14.7 to 1 Air Fuel (A/F) ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxide (NOx) from the exhaust. The voltage readings taken from the O2S are very temperature sensitive. The readings are not accurate below 300°C. Heating of the O2S is done to allow the engine controller to shift to closed loop control as soon as possible. The heating element used to heat the O2S must be tested to ensure that it is heating the sensor properly. The O2S circuit is monitored for a drop in voltage. The sensor output is used to test the heater by isolating the effect of the heater element on the O2S output voltage from the other effects. EGR MONITOR (if equipped) The Powertrain Control Module (PCM) performs an on-board diagnostic check of the EGR system. The EGR monitor is used to test whether the EGR system is operating within specifications. The diagnostic check activates only during selected engine/ driving conditions. When the conditions are met, the EGR is turned off (solenoid energized) and the O2S compensation control is monitored. Turning off the EGR shifts the air fuel (A/F) ratio in the lean direction. The O2S data should indicate an increase in the O2 concentration in the combustion chamber when the exhaust gases are no longer recirculated. While this test does not directly measure the operation of the EGR system, it can be inferred from the shift in the O2S data whether the EGR system is operating correctly. Because the O2S is being used, the O2S test must pass its test before the EGR test. Also looks at EGR linear potentiometer for feedback. MISFIRE MONITOR Excessive engine misfire results in increased catalyst temperature and causes an increase in HC emissions. Severe misfires could cause catalyst damage. To prevent catalytic convertor damage, the PCM monitors engine misfire. The Powertrain Control Module (PCM) monitors for misfire during most engine operating conditions (positive torque) by looking at changes in the crankshaft speed. If a misfire occurs the speed of the crankshaft will vary more than normal. FUEL SYSTEM MONITOR To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide. The catalyst works best when the air fuel (A/F) ratio is at or near the optimum of 14.7 to 1. The PCM is programmed to maintain the optimum air/fuel ratio. This is done by making short term corrections in the fuel injector pulse width based on the O2S output. The programmed memory acts as a self calibration tool that the engine controller uses to compensate for variations in engine specifications, sensor tolerances and engine fatigue over the life span of the engine. By monitoring the actual air-fuel ratio with the O2S (short term) and multiplying that with the program long-term (adaptive) memory and comparing that to the limit, it can be determined whether it will pass an emissions test. If a malfunction occurs such that the PCM cannot maintain the optimum A/F ratio, then the MIL will be illuminated. CATALYST MONITOR To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide. Normal vehicle miles or engine misfire can cause a catalyst to decay. A meltdown of the ceramic core can cause a reduction of the exhaust passage. This can increase vehicle emissions and deteriorate engine performance, driveability and fuel economy. The catalyst monitor uses dual oxygen sensors (O2S’s) to monitor the efficiency of the converter. The dual O2S’s strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter. The PCM calculates the A/F mixture from the output of the O2S. A low voltage indicates high oxygen content (lean mixture). A high voltage indicates a low content of oxygen (rich mixture). When the upstream O2S detects a lean condition, there is an abundance of oxygen in the exhaust gas. A functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstream O2S will indicate limited activity in this condition. As the converter loses the ability to store oxygen, the condition can be detected from the behavior of the downstream O2S. When the efficiency drops, no 25 - 8 EMISSIONS CONTROL RS EMISSIONS CONTROL (Continued) chemical reaction takes place. This means the concentration of oxygen will be the same downstream as upstream. The output voltage of the downstream O2S copies the voltage of the upstream sensor. The only difference is a time lag (seen by the PCM) between the switching of the O2S’s. To monitor the system, the number of lean-to-rich switches of upstream and downstream O2S’s is counted. The ratio of downstream switches to upstream switches is used to determine whether the catalyst is operating properly. An effective catalyst will have fewer downstream switches than it has upstream switches i.e., a ratio closer to zero. For a totally ineffective catalyst, this ratio will be one-toone, indicating that no oxidation occurs in the device. The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over the legal limit, the MIL (Check Engine lamp) will be illuminated. LEAK DETECTION PUMP MONITOR (if equipped) The leak detection assembly incorporates two primary functions: it must detect a leak in the evaporative system and seal the evaporative system so the leak detection test can be run. The primary components within the assembly are: A three port solenoid that activates both of the functions listed above; a pump which contains a switch, two check valves, a spring/diaphragm, and a canister vent valve (CVV) seal which contains a spring loaded vent seal valve. Immediately after a cold start, between predetermined temperature thresholds limits, the three port solenoid is briefly energized. This initializes the pump by drawing air into the pump cavity and also closes the vent seal. During non test conditions the vent seal is held open by the pump diaphragm assembly which pushes it open at the full travel position. The vent seal will remain closed while the pump is cycling due to the reed switch triggering of the three port solenoid that prevents the diaphragm assembly from reaching full travel. After the brief initialization period, the solenoid is de-energized allowing atmospheric pressure to enter the pump cavity, thus permitting the spring to drive the diaphragm which forces air out of the pump cavity and into the vent system. When the solenoid is energized and de energized, the cycle is repeated creating flow in typical diaphragm pump fashion. The pump is controlled in 2 modes: Pump Mode: The pump is cycled at a fixed rate to achieve a rapid pressure build in order to shorten the overall test length. Test Mode: The solenoid is energized with a fixed duration pulse. Subsequent fixed pulses occur when the diaphragm reaches the Switch closure point. The spring in the pump is set so that the system will achieve an equalized pressure of about 7.5” water. The cycle rate of pump strokes is quite rapid as the system begins to pump up to this pressure. As the pressure increases, the cycle rate starts to drop off. If there is no leak in the system, the pump would eventually stop pumping at the equalized pressure. If there is a leak, it will continue to pump at a rate representative of the flow characteristic of the size of the leak. From this information we can determine if the leak is larger than the required detection limit (currently set at .020” orifice by CARB). If a leak is revealed during the leak test portion of the test, the test is terminated at the end of the test mode and no further system checks will be performed. The canister vent valve will unseal the system after completion of the test sequence as the pump diaphragm assembly moves to the full travel position. Evaporative system functionality will be verified by using the stricter evap purge flow monitor. At an appropriate warm idle the LDP will be energized to seal the canister vent. The purge flow will be clocked up from some small value in an attempt to see a shift in the 02 control system. If fuel vapor, indicated by a shift in the 02 control, is present the test is passed. If not, it is assumed that the purge system is not functioning in some respect. The LDP is again turned off and the test is ended. Natural Vacuum Leak Detection (NVLD) (if equipped) The Natural Vacuum Leak Detection (NVLD) system is the next generation evaporative leak detection system that will first be used on vehicles equipped with the Next Generation Controller (NGC) starting in 2002 M.Y. This new system replaces the leak detection pump as the method of evaporative system leak detection. This is to detect a leak equivalent to a 0.0209 (0.5 mm) hole. This system has the capability to detect holes of this size very dependably. The basic leak detection theory employed with NVLD is the 9Gas Law9. This is to say that the pressure in a sealed vessel will change if the temperature of the gas in the vessel changes. The vessel will only see this effect if it is indeed sealed. Even small leaks will allow the pressure in the vessel to come to equilibrium with the ambient pressure. In addition to the detection of very small leaks, this system has the capability of detecting medium as well as large evaporative system leaks. A vent valve seals the canister vent during engine off conditions. If the vapor system has a leak of less than the failure threshold, the evaporative system will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. The diurnal effect is considered one of the primary contributors to the leak determi- EMISSIONS CONTROL RS 25 - 9 EMISSIONS CONTROL (Continued) nation by this diagnostic. When the vacuum in the system exceeds about 19 H2O (0.25 KPA), a vacuum switch closes. The switch closure sends a signal to the NGC. The NGC, via appropriate logic strategies (described below), utilizes the switch signal, or lack thereof, to make a determination of whether a leak is present. The NVLD device is designed with a normally open vacuum switch, a normally closed solenoid, and a seal, which is actuated by both the solenoid and a diaphragm. The NVLD is located on the atmospheric vent side of the canister. The NVLD assembly may be mounted on top of the canister outlet, or in-line between the canister and atmospheric vent filter. The normally open vacuum switch will close with about 19 H2O (0.25 KPA) vacuum in the evaporative system. The diaphragm actuates the switch. This is above the opening point of the fuel inlet check valve in the fill tube so cap off leaks can be detected. Submerged fill systems must have recirculation lines that do not have the in-line normally closed check valve that protects the system from failed nozzle liquid ingestion, in order to detect cap off conditions. The normally closed valve in the NVLD is intended to maintain the seal on the evaporative system during the engine off condition. If vacuum in the evaporative system exceeds 39 to 69 H2O (0.75 to 1.5 KPA), the valve will be pulled off the seat, opening the seal. This will protect the system from excessive vacuum as well as allowing sufficient purge flow in the event that the solenoid was to become inoperative. The solenoid actuates the valve to unseal the canister vent while the engine is running. It also will be used to close the vent during the medium and large leak tests and during the purge flow check. This solenoid requires initial 1.5 amps of current to pull the valve open but after 100 ms. will be duty cycled down to an average of about 150 mA for the remainder of the drive cycle. Another feature in the device is a diaphragm that will open the seal in the NVLD with pressure in the evaporative system. The device will 9blow off9 at about 0.59 H2O (0.12 KPA) pressure to permit the venting of vapors during refueling. An added benefit to this is that it will also allow the tank to 9breathe9 during increasing temperatures, thus limiting the pressure in the tank to this low level. This is beneficial because the induced vacuum during a subsequent declining temperature will achieve the switch closed (pass threshold) sooner than if the tank had to decay from a built up pressure. The device itself has 3 wires: Switch sense, solenoid driver and ground. It also includes a resistor to protect the switch from a short to battery or a short to ground. The NGC utilizes a high-side driver to energize and duty-cycle the solenoid. DESCRIPTION - HIGH AND LOW LIMITS The PCM compares input signal voltages from each input device with established high and low limits for the device. If the input voltage is not within limits and other criteria are met, the PCM stores a diagnostic trouble code in memory. Other diagnostic trouble code criteria might include engine RPM limits or input voltages from other sensors or switches that must be present before verifying a diagnostic trouble code condition. OPERATION OPERATION - SYSTEM The Powertrain Control Module (PCM) monitors many different circuits in the fuel injection, ignition, emission and engine systems. If the PCM senses a problem with a monitored circuit often enough to indicate an actual problem, it stores a Diagnostic Trouble Code (DTC) in the PCM’s memory. If the code applies to a non-emissions related component or system, and the problem is repaired or ceases to exist, the PCM cancels the code after 40 warmup cycles. Diagnostic trouble codes that affect vehicle emissions illuminate the Malfunction Indicator Lamp (MIL). Refer to Malfunction Indicator Lamp in this section. Certain criteria must be met before the PCM stores a DTC in memory. The criteria may be a specific range of engine RPM, engine temperature, and/or input voltage to the PCM. The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred. This may happen because one of the DTC criteria for the circuit has not been met. For example , assume the diagnostic trouble code criteria requires the PCM to monitor the circuit only when the engine operates between 750 and 2000 RPM. Suppose the sensor’s output circuit shorts to ground when engine operates above 2400 RPM (resulting in 0 volt input to the PCM). Because the condition happens at an engine speed above the maximum threshold (2000 rpm), the PCM will not store a DTC. There are several operating conditions for which the PCM monitors and sets DTC’s. Refer to Monitored Systems, Components, and Non-Monitored Circuits in this section. NOTE: Various diagnostic procedures may actually cause a diagnostic monitor to set a DTC. For instance, pulling a spark plug wire to perform a spark test may set the misfire code. When a repair is completed and verified, use the DRBIIIT scan tool to erase all DTC’s and extinguish the MIL. 25 - 10 EMISSIONS CONTROL RS EMISSIONS CONTROL (Continued) Technicians can display stored DTC’s. Refer to Diagnostic Trouble Codes (Refer to 8 - ELECTRICAL/ ELECTRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE - DESCRIPTION). For obtaining the DTC information, use the Data Link Connector with the DRBIIIt scan tool (Fig. 1). DRB IIIT STATE DISPLAY TEST MODE OPERATION The switch inputs to the Powertrain Control Module (PCM) have two recognized states; HIGH and LOW. For this reason, the PCM cannot recognize the difference between a selected switch position versus an open circuit, a short circuit, or a defective switch. If the State Display screen shows the change from HIGH to LOW or LOW to HIGH, assume the entire switch circuit to the PCM functions properly. From the state display screen, access either State Display Inputs and Outputs or State Display Sensors. Fig. 1 Data Link Connector EVAPORATIVE EMISSIONS RS 25 - 11 EVAPORATIVE EMISSIONS TABLE OF CONTENTS page page EVAPORATIVE EMISSIONS OPERATION - EVAPORATION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 EVAP/PURGE SOLENOID DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 FUEL FILLER CAP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 LEAK DETECTION PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 ORVR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 DIAGNOSIS AND TESTING - VEHICLE DOES NOT FILL . . . . . . . . . . . . . . . . . . . . . . . . . PCV VALVE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - PCV SYSTEM VAPOR CANISTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - REAR EVAP CANISTER . . . . INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . INSTALLATION - REAR EVAP CANISTER EVAPORATIVE EMISSIONS All engines use a proportional purge solenoid system. The PCM controls vapor flow by operating the purge solenoid. Refer to Proportional Purge Solenoid in this section. OPERATION - EVAPORATION CONTROL SYSTEM The evaporation control system prevents the emission of fuel tank vapors into the atmosphere. When fuel evaporates in the fuel tank, the vapors pass through vent hoses or tubes to an activated carbon filled evaporative canister. The canister temporarily holds the vapors. The Powertrain Control Module (PCM) allows intake manifold vacuum to draw vapors into the combustion chambers during certain operating conditions (Fig. 1). . . . 16 . . . 17 . . . 17 . . . 17 . . . 18 . . . 18 . . . 19 . . . 19 . . . 19 . . . 19 NOTE: The evaporative system uses specially manufactured hoses. If they need replacement, only use fuel resistant hose. Also the hoses must be able to pass an Ozone compliance test. NOTE: For more information on Onboard Refueling Vapor Recovery (ORVR), refer to the Fuel Delivery section. 25 - 12 EVAPORATIVE EMISSIONS RS EVAPORATIVE EMISSIONS (Continued) Fig. 1 ORVR System Schematic 1 2 3 4 5 6 7 - FUEL CAP RECIRCULATION TUBE LIQUID SEPARATOR PURGE SOLENOID W/LDP BREATHER ELEMENT W/O LDP 8 - CANISTER 9 - ROLLOVER VALVE 10 - FUEL TANK 11 - CHECK VALVE 12 - CONTROL VALVE SPECIFICATIONS TORQUE DESCRIPTION N·m PCV VAlve 3.3/3.8L 6.3 Ft. Lbs. In. Lbs. 55 EVAPORATIVE EMISSIONS RS 25 - 13 EVAP/PURGE SOLENOID DESCRIPTION All vehicles use a proportional purge solenoid (Fig. 2). The solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. Fig. 3 EVAP PURGE SOLENOID 1 - EVAP Purge Solenoid 2 - EGR VAlve 3 - Generator Fig. 2 Proportional Purge Solenoid OPERATION 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. REMOVAL The solenoid attaches to a bracket near the radiator on the passenger side of vehicle (Fig. 3). The solenoid will not operate unless it is installed correctly. (1) Disconnect electrical connector from solenoid. (2) Disconnect vacuum tubes from solenoid. (3) Remove solenoid from bracket. INSTALLATION The solenoid attaches to a bracket near the radiator on the passenger side of vehicle. The solenoid will not operate unless it is installed correctly. The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly. (1) Install solenoid on bracket. (2) Connect vacuum tube to solenoid. (3) Connect electrical connector to solenoid. FUEL FILLER CAP 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. 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 2 kPa (0.6 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. 25 - 14 EVAPORATIVE EMISSIONS LEAK DETECTION PUMP REMOVAL (1) Disconnect the negative battery cable. (2) Raise and support the vehicle. RS INSTALLATION (1) (2) (3) (4) (5) (6) Install LDP. Install the 3 screws and tighten (Fig. 5). Install the electrical connector. Install the 3 hoses (Fig. 4). Lower vehicle. Connect the negative battery cable. ORVR OPERATION Fig. 4 LDP LOCATION (3) Remove 3 hoses (Fig. 4). (4) Remove the electrical connector (Fig. 5). Fig. 5 LDP REMOVAL/INSTALLATION (5) Remove the 3 screws and remove LDP pump. The emission control principle used in the ORVR system is that the fuel flowing into the filler tube (appx. 1” I.D.) creates an aspiration effect which draws air into the fill tube (Fig. 6). During refueling, the fuel tank is vented to the vapor canister to capture escaping vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the canister, the vehicle’s computer controlled purge system draws vapor out of the canister for the engine to burn. The vapors flow is metered by the purge solenoid so that there is no or minimal impact on driveability or tailpipe emissions. As fuel starts to flow through the fill tube, it opens the normally closed check valve and enters the fuel tank. Vapor or air is expelled from the tank through the control valve to the vapor canister. Vapor is absorbed in the canister until vapor flow in the lines stops, either following shut-off or by having the fuel level in the tank rise high enough to close the control valve. The control valve(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - OPERATION) contains a float that rises to seal the large diameter vent path to the canister. At this point in the fueling of the vehicle, the tank pressure increases, the check valve closes (preventing tank fuel from spitting back at the operator), and fuel then rises up the filler tube to shut-off the dispensing nozzle. If the engine is shut-off while the On-Board diagnostics test is running, low level tank pressure can be trapped in the fuel tank and fuel can not be added to the tank until the pressure is relieved. This is due to the leak detection pump closing the vapor outlet from the top of the tank and the one-way check valve not allowing the tank to vent through the fill tube to atmosphere. Therefore, when fuel is added, it will back-up in the fill tube and shut off the dispensing nozzle. The pressure can be eliminated in two ways: 1. Vehicle purge must be activated and for a long enough period to eliminate the pressure. 2. Removing the fuel cap and allowing enough time for the system to vent thru the recirulation tube. EVAPORATIVE EMISSIONS RS ORVR (Continued) Fig. 6 ORVR System Schematic 1 2 3 4 5 6 7 - FUEL CAP RECIRCULATION TUBE LIQUID SEPARATOR PURGE SOLENOID W/LDP BREATHER ELEMENT W/O LDP 8 - CANISTER 9 - ROLLOVER VALVE 10 - FUEL TANK 11 - CHECK VALVE 12 - CONTROL VALVE 25 - 15 25 - 16 EVAPORATIVE EMISSIONS RS ORVR (Continued) DIAGNOSIS AND TESTING - VEHICLE DOES NOT FILL CONDITION Pre-Mature Nozzle Shut-Off POSSIBLE CAUSES Defective fuel tank assembly components. CORRECTION Fill tube improperly installed (sump) Fill tube hose pinched. Check valve stuck shut. Control valve stuck shut. Defective vapor/vent components. Vent line from control valve to canister pinched. Vent line from canister to vent filter pinched. Canister vent valve failure (requires double failure, plugged to LDP and atmosphere). Leak detection pump failed closed. Leak detection pump filter plugged. On-Board diagnostics evaporative system leak test just conducted. Canister vent valve vent plugged to atmosphere. engine still running when attempting to fill (System designed not to fill). Fuel Spits Out Of Filler Tube. Defective fill nozzle. Try another nozzle. During fill. See Pre-Mature Shut-Off. At conclusion of fill. Defective fuel handling component. (Check valve stuck open). Defective vapor/vent handling component. Defective fill nozzle. EVAPORATIVE EMISSIONS RS 25 - 17 PCV VALVE OPERATION DESCRIPTION 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 (Fig. 9). The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum (Fig. 7) or (Fig. 8). Fig. 9 Engine Off or Engine Backfire No Vapor Flow 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 (Fig. 10). In this position there is minimal vapor flow through the valve. Fig. 7 PCV VALVE 2.4L Fig. 10 High Intake Manifold Vacuum Minimal Vapor Flow 1 - PCV 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 (Fig. 11). Fig. 11 Moderate Intake Manifold Vacuum Maximum Vapor Flow DIAGNOSIS AND TESTING - PCV SYSTEM Fig. 8 PCV VALVE 3.3/3.8L WARNING: APPLY PARKING BRAKE AND/OR BLOCK WHEELS BEFORE PERFORMING ANY TEST OR ADJUSTMENT WITH THE ENGINE OPERATING. (1) With engine idling, remove the hose from the PCV valve. If the valve is not plugged, a hissing 25 - 18 EVAPORATIVE EMISSIONS RS PCV VALVE (Continued) noise will be heard as air passes through the valve. A strong vacuum should also be felt when a finger is placed over the valve inlet. (2) Install hose on PCV valve. Remove the make-up air hose from the air plenum at the rear of the engine. Hold a piece of stiff paper (parts tag) loosely over the end of the make-up air hose. (3) After allowing approximately one minute for crankcase pressure to reduce, the paper should draw up against the hose with noticeable force. If the engine does not draw the paper against the grommet after installing a new valve, replace the PCV valve hose. (4) Turn the engine off. Remove the PCV valve from intake manifold. The valve should rattle when shaken. (5) Replace the PCV valve and retest the system if it does not operate as described in the preceding tests. Do not attempt to clean the old PCV valve. If the valve rattles, apply a light coating of Loctitet Pipe Sealant With Teflon to the threads. Thread the PCV valve into the manifold plenum and tighten to 7 N·m (60 in. lbs.) torque. VAPOR CANISTER Fig. 12 FRONT EVAP CANISTER 1 - Front EVAP Canister 2 - Vent Valve DESCRIPTION There are 2 EVAP canisters on the vehicle. The vacuum and vapor tubes connect to the top of the canister. It is a charcoal canister (Fig. 12) or (Fig. 13). 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 DRB IIIt 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. Fig. 13 REAR EVAP CANISTER 1 - Rear EVAP Canister 2 - Front EVAP Canister 3 - Vent Valve EVAPORATIVE EMISSIONS RS 25 - 19 VAPOR CANISTER (Continued) REMOVAL REMOVAL (1) (2) (3) (4) Raise and support the vehicle. Remove the 2 hoses (Fig. 12). Remove bolt. Pull canister rearward to remove. (2) Install bolt and tighten. (3) Install hoses. (4) Lower vehicle. INSTALLATION - REAR EVAP CANISTER (1) Install canister arrow heads into the rubber gromments (Fig. 15). REMOVAL - REAR EVAP CANISTER (1) (2) (3) (4) Raise and support the vehicle. Remove 3 hoses (Fig. 13). Remove the bolt. Pull rearward to remove canister. INSTALLATION INSTALLATION (1) Install canister arrow heads into the rubber gromments (Fig. 14) Fig. 15 REAR EVAP CANISTER BRACKET (2) Install bolt and tighten. (3) Install hoses. (4) Lower vehicle. Fig. 14 FRONT EVAP CANISTER BRACKET 25 - 20 EXHAUST GAS RECIRCULATION RS EXHAUST GAS RECIRCULATION TABLE OF CONTENTS page EXHAUST GAS RECIRCULATION SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . . TUBE REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . . REMOVAL - FRONT TUBE- 3.5L . . . REMOVAL - REAR TUBE - 3.5L . . . . INSTALLATION INSTALLATION - 2.4L ........... INSTALLATION - FRONT TUBE - 3.5L . . . . . . . 20 . . . . . . . 20 . . . . . . . 20 . . . . . . . 21 . . . . . . . 21 . . . . . . 21 page INSTALLATION - REAR TUBE - 3.5L VALVE DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . REMOVAL - 3.5L . . . . . . . . . . . . . . INSTALLATION INSTALLATION - 2.4L .......... INSTALLATION - 3.5L .......... . . . . . . . 21 . . . . . . . . 21 . . . . . . . . 21 . . . . . . . . 23 . . . . . . . . 23 . . . . . . . . 23 . . . . . . . . 23 EXHAUST GAS RECIRCULATION SPECIFICATIONS TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. EGR valve to cyl. head 2.4L 22 - 200 ±25 EGR tube to EGR valve 2.4L 11.9 - 105 ±20 EGR tube to intake manifold 2.4L 11.9 - 105 ±20 EGR valve to adaptor 3.3/3.8L 22 - 200 ±25 EGR tube to EGR valve 3.3/3.8L 11.9 - 105 ±20 EGR tube to intake manifold 3.3L 5.6 - 50 ±10 EGR tube to intake manifold 3.8L 11.9 - 105 ±20 TUBE REMOVAL REMOVAL - 2.4L (1) Remove EGR tube attaching bolts at intake manifold. (2) Remove EGR tube attaching bolts at EGR valve. (3) Check for signs of leakage or cracked surfaces on either the manifold or tube. Repair or replace as necessary. REMOVAL - FRONT TUBE- 3.5L (1) Disconnect the negative battery cable. EXHAUST GAS RECIRCULATION RS 25 - 21 TUBE (Continued) (2) Disconnect the fresh air makeup hose on rear valve cover. (3) Remove the air box bolt. (4) Remove the hose clamp at throttle body. (5) Unlatch 2 clamps for air box cover. (6) Remove air box cover. (7) Disconnect the washer fluid fill hose. (8) Remove air box. (9) Remove the 2 bolts at the EGR valve. (10) Remove the 2 bolts at the intake manifold. (11) Remove front EGR tube. REMOVAL - REAR TUBE - 3.5L (1) Remove tion. (2) Remove (3) Remove and relocate. (4) Remove (5) Remove head. (6) Remove the battery, refer to the Battery secthe Battery tray/vacuum reservoir. the speed control servo and bracket (5) Install the speed control servo and bracket, refer to the speed control section. (6) Install the Battery tray/vacuum reservoir refer to the battery section. (7) Install the battery, refer to the Battery section. VALVE DESCRIPTION The EGR system consists of: • EGR tube (connects a passage in the intake manifold to the exhaust port in the cylinder head) • EGR valve • Electronic EGR Transducer • Connecting hoses the 2 bolts from the EGR valve. the 2 bolts from the rear cylinder the EGR rear tube. INSTALLATION INSTALLATION - 2.4L (1) Loose install EGR tube and gasket with attaching bolts at intake manifold. (2) Loose install EGR tube and gasket with attaching bolts at EGR valve. (3) Tighten bolts to EGR valve to 11.9 N·m (105 ±20 ins. lbs.). (4) Tighten bolts to Intake manifold to 11.9 N·m (105 ±20 ins. lbs.). INSTALLATION - FRONT TUBE - 3.5L (1) Install front EGR tube and gaskets. (2) Install the 2 bolts at the EGR valve. (3) Install the 2 bolts at the intake manifold. (4) Tighten all 4 bolts. (5) Install air box. (6) Connect the washer fluid fill hose. (7) Install air box cover. (8) Latch 2 clamps for air box cover. (9) Install the hose clamp at throttle body. (10) Install the air box bolt. (11) Connect the fresh air makeup hose on rear valve cover. (12) Connect the negative battery cable. INSTALLATION - REAR TUBE - 3.5L (1) (2) (3) (4) Install the EGR rear tube. Install the 2 bolts to the rear cylinder head. Install the 2 bolts to the EGR valve. Tighten the 4 bolts. Fig. 1 EGR VALVE AND TUBE 2.4L 1 - EGR Tube 2 - EGR Valve OPERATION Refer to Monitored Systems - EGR Monitor in this group for more information. The engines use Exhaust Gas Recirculation (EGR) systems. The EGR system reduces oxides of nitrogen (NOx) in engine exhaust and helps prevent detonation (engine knock). Under normal operating conditions, engine cylinder temperature can reach more than 3000°F. Formation of NOx increases proportionally with combustion temperature. To reduce the emission of these oxides, the cylinder temperature must be lowered. The system allows a predetermined amount of hot exhaust gas to recirculate and dilute 25 - 22 EXHAUST GAS RECIRCULATION RS VALVE (Continued) Fig. 2 EGR VALVE AND TUBE 3.3/3.8L the incoming air/fuel mixture. The diluted air/fuel mixture reduces peak flame temperature during combustion. The electric EGR transducer contains an electrically operated solenoid and a back-pressure transducer (Fig. 3). The Powertrain Control Module (PCM) operates the solenoid. The PCM determines when to energize the solenoid. Exhaust system back-pressure controls the transducer. When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to the transducer when the PCM de-energizes the solenoid. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. This system does not allow EGR at idle. A failed or malfunctioning EGR system can cause engine spark knock, sags or hesitation, rough idle, engine stalling and increased emissions. Fig. 3 EGR Valve and Transducer - Typical 1 - DIAPHRAGM 2 - PISTON 3 - SPRING 4 - EGR VALVE ASSEMBLY 5 - VACUUM MOTOR 6 - VACUUM MOTOR FITTING 7 - VACUUM OUTLET FITTING TO EGR VALVE 8 - EGR VALVE CONTROL ASSEMBLY 9 - ELECTRIC SOLENOID PORTION OF VALVE CONTROL 10 - VACUUM INLET FITTING FROM ENGINE 11 - BACK-PRESSURE HOSE 12 - TRANSDUCER PORTION OF VALVE CONTROL 13 - ELECTRICAL CONNECTION POINT 14 - EGR VALVE BACK-PRESSURE FITTING 15 - EXHAUST GAS INLET 16 - STEM PROTECTOR AND BUSHING 17 - BASE 18 - MOVEMENT INDICATOR 19 - POPPET VALVE 20 - SEAT 21 - EXHAUST GAS OUTLET RS EXHAUST GAS RECIRCULATION 25 - 23 VALVE (Continued) REMOVAL INSTALLATION REMOVAL - 2.4L INSTALLATION - 2.4L The EGR valve and Electrical EGR Transducer are serviced as an assembly (Fig. 1). (1) Disconnect vacuum tube from electric EGR transducer. Inspect vacuum tube for damage. (2) Remove electrical connector from solenoid. (3) Remove EGR tube bolts from EGR valve. (4) Remove EGR valve from cylinder head adaptor. (5) Clean gasket surface and discard old gasket. Check for any signs of leakage or cracked surfaces. Repair or replace as necessary. The EGR valve and Electrical EGR Transducer are serviced as an assembly (Fig. 1). (1) Assemble EGR valve with new gasket onto the cylinder head adaptor. (2) Loose assemble the bolts from EGR valve to EGR tube. (3) Loose assemble the bolts from EGR valve to cylinder head. (4) Tighten bolts from EGR valve to cylinder head to 22.8 N·m (200 ±25 in. lbs.) torque. (5) Tighten bolts from EGR valve to EGR tube to 11.9 N·m (105 ±20 in. lbs.) torque. (6) Reconnect vacuum hose and electrical connector to electrical EGR transducer. REMOVAL - 3.5L (1) Disconnect the negative battery cable. (2) Disconnect the fresh air makeup hose on rear valve cover. (3) Remove the air box bolt. (4) Remove the hose clamp at throttle body. (5) Unlatch 2 clamps for air box cover. (6) Remove air box cover. (7) Unlock the electrical connector. (8) Disconnect the electrical connector from the EGR valve. (9) Remove the 2 bolts for the front EGR tube (10) Remove the 2 bolts for the rear EGR tube (11) Remove the 2 EGR valve mounting bolts. (12) Remove the EGR valve. INSTALLATION - 3.5L (1) Install the EGR valve. (2) Install the 2 bolts for the rear EGR tube (3) Install the 2 bolts for the front EGR tube (4) Tighten the EGR tube bolts. (5) Tighten the EGR valve mounting bolts. (6) Connect the electrical connector to the EGR valve. (7) Lock the electrical connector. (8) Install air box cover. (9) Latch 2 clamps for air box cover. (10) Install the hose clamp at throttle body. (11) Connect the fresh air makeup hose on rear valve cover. (12) Connect the negative battery cable. 25 - 24 ON-BOARD DIAGNOSTICS RS ON-BOARD DIAGNOSTICS TABLE OF CONTENTS page TASK MANAGER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 TASK MANAGER DESCRIPTION The PCM is responsible for efficiently coordinating the operation of all the emissions-related components. The PCM is also responsible for determining if the diagnostic systems are operating properly. The software designed to carry out these responsibilities is call the “Task Manager”. OPERATION The Task Manager determines when tests happen and when functions occur. Many of the diagnostic steps required by OBD II must be performed under specific operating conditions. The Task Manager software organizes and prioritizes the diagnostic procedures. The job of the Task Manager is to determine if conditions are appropriate for tests to be run, monitor the parameters for a trip for each test, and record the results of the test. Following are the responsibilities of the Task Manager software: • Test Sequence • MIL Illumination • Diagnostic Trouble Codes (DTCs) • Trip Indicator • Freeze Frame Data Storage • Similar Conditions Window Test Sequence In many instances, emissions systems must fail diagnostic tests more than once before the PCM illuminates the MIL. These tests are know as ’two trip monitors.’ Other tests that turn the MIL lamp on after a single failure are known as ’one trip monitors.’ A trip is defined as ’start the vehicle and operate it to meet the criteria necessary to run the given monitor.’ Many of the diagnostic tests must be performed under certain operating conditions. However, there are times when tests cannot be run because another test is in progress (conflict), another test has failed (pending) or the Task Manager has set a fault that may cause a failure of the test (suspend). • Pending Under some situations the Task Manager will not page OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 run a monitor if the MIL is illuminated and a fault is stored from another monitor. In these situations, the Task Manager postpones monitors pending resolution of the original fault. The Task Manager does not run the test until the problem is remedied. For example, when the MIL is illuminated for an Oxygen Sensor fault, the Task Manager does not run the Catalyst Monitor until the Oxygen Sensor fault is remedied. Since the Catalyst Monitor is based on signals from the Oxygen Sensor, running the test would produce inaccurate results. • Conflict There are situations when the Task Manager does not run a test if another monitor is in progress. In these situations, the effects of another monitor running could result in an erroneous failure. If this conflict is present, the monitor is not run until the conflicting condition passes. Most likely the monitor will run later after the conflicting monitor has passed. For example, if the Fuel System Monitor is in progress, the Task Manager does not run the catalyst Monitor. Since both tests monitor changes in air/fuel ratio and adaptive fuel compensation, the monitors will conflict with each other. • Suspend Occasionally the Task Manager may not allow a two trip fault to mature. The Task Manager will suspend the maturing of a fault if a condition exists that may induce an erroneous failure. This prevents illuminating the MIL for the wrong fault and allows more precise diagnosis. For example, if the PCM is storing a one trip fault for the Oxygen Sensor and the catalyst monitor, the Task Manager may still run the catalyst Monitor but will suspend the results until the Oxygen Sensor Monitor either passes or fails. At that point the Task Manager can determine if the catalyst system is actually failing or if an Oxygen Sensor is failing. MIL Illumination The PCM Task Manager carries out the illumination of the MIL. The Task Manager triggers MIL illumination upon test failure, depending on monitor failure criteria. RS ON-BOARD DIAGNOSTICS 25 - 25 TASK MANAGER (Continued) The Task Manager Screen shows both a Requested MIL state and an Actual MIL state. When the MIL is illuminated upon completion of a test for a good trip, the Requested MIL state changes to OFF. However, the MIL remains illuminated until the next key cycle. (On some vehicles, the MIL will actually turn OFF during the third key cycle) During the key cycle for the third good trip, the Requested MIL state is OFF, while the Actual MIL state is ON. After the next key cycle, the MIL is not illuminated and both MIL states read OFF. Diagnostic Trouble Codes (DTCs) With OBD II, different DTC faults have different priorities according to regulations. As a result, the priorities determine MIL illumination and DTC erasure. DTCs are entered according to individual priority. DTCs with a higher priority overwrite lower priority DTCs. Priorities • Priority 0 —Non-emissions related trouble codes. • Priority 1 — One trip failure of a two trip fault for non-fuel system and non-misfire. (MIL Off) • Priority 2 — One trip failure of a two trip fault for fuel system (rich/lean) or misfire. (MIL Off) • Priority 3 — Two trip failure for a non-fuel system and non-misfire or matured one trip comprehensive component fault. (MIL On) • Priority 4 — Two trip failure or matured fault for fuel system (rich/lean) and misfire or one trip catalyst damaging misfire. Catalyst damage misfire is a 2 trip MIL. The MIL flashes on the first trip when catalyst damage misfire levels are present. (MIL On) Non-emissions related failures have no priority. One trip failures of two trip faults have low priority. Two trip failures or matured faults have higher priority. One and two trip failures of fuel system and misfire monitor take precedence over non-fuel system and non-misfire failures. DTC Self Erasure With one trip components or systems, the MIL is illuminated upon test failure and DTCs are stored. Two trip monitors are components requiring failure in two consecutive trips for MIL illumination. Upon failure of the first test, the Task Manager enters a maturing code. If the component fails the test for a second time the code matures and a DTC is set. After three good trips the MIL is extinguished and the Task Manager automatically switches the trip counter to a warm-up cycle counter. DTCs are automatically erased following 40 warm-up cycles if the component does not fail again. For misfire and fuel system monitors, the component must pass the test under a Similar Conditions Window in order to record a good trip. A Similar Con- ditions Window is when engine RPM is within ±375 RPM and load is within ±20% of when the fault occurred. NOTE: It is important to understand that a component does not have to fail under a similar window of operation to mature. It must pass the test under a Similar Conditions Window when it failed to record a Good Trip for DTC erasure for misfire and fuel system monitors. DTCs can be erased anytime with a DRBIIIt. Erasing the DTC with the DRBIIIt erases all OBD II information. The DRBIIIt automatically displays a warning that erasing the DTC will also erase all OBD II monitor data. This includes all counter information for warm-up cycles, trips and Freeze Frame. Trip Indicator The Trip is essential for running monitors and extinguishing the MIL. In OBD II terms, a trip is a set of vehicle operating conditions that must be met for a specific monitor to run. All trips begin with a key cycle. Good Trip The Good Trip counters are as follows: • Global Good Trip • Fuel System Good Trip • Misfire Good Trip • Alternate Good Trip (appears as a Global Good Trip on DRBIIIt) • Comprehensive Components • Major Monitor • Warm-Up Cycles Global Good Trip To increment a Global Good Trip, the Oxygen sensor and Catalyst efficiency monitors must have run and passed, and 2 minutes of engine run time. Fuel System Good Trip To count a good trip (three required) and turn off the MIL, the following conditions must occur: • Engine in closed loop • Operating in Similar Conditions Window • Short Term multiplied by Long Term less than threshold • Less than threshold for a predetermined time If all of the previous criteria are met, the PCM will count a good trip (three required) and turn off the MIL. Misfire Good Trip If the following conditions are met the PCM will count one good trip (three required) in order to turn off the MIL: • Operating in Similar Condition Window • 1000 engine revolutions with no misfire Alternate Good Trip 25 - 26 ON-BOARD DIAGNOSTICS RS TASK MANAGER (Continued) Alternate Good Trips are used in place of Global Good Trips for Comprehensive Components and Major Monitors. If the Task Manager cannot run a Global Good Trip because a component fault is stopping the monitor from running, it will attempt to count an Alternate Good Trip. The Task Manager counts an Alternate Good Trip for Comprehensive components when the following conditions are met: • Two minutes of engine run time, idle or driving • No other faults occur The Task Manager counts an Alternate Good Trip for a Major Monitor when the monitor runs and passes. Only the Major Monitor that failed needs to pass to count an Alternate Good Trip. Warm-Up Cycles Once the MIL has been extinguished by the Good Trip Counter, the PCM automatically switches to a Warm-Up Cycle Counter that can be viewed on the DRBIIIt. Warm-Up Cycles are used to erase DTCs and Freeze Frames. Forty Warm-Up cycles must occur in order for the PCM to self-erase a DTC and Freeze Frame. A Warm-Up Cycle is defined as follows: • Engine coolant temperature must start below and rise above 160° F • Engine coolant temperature must rise by 40° F • No further faults occur Freeze Frame Data Storage Once a failure occurs, the Task Manager records several engine operating conditions and stores it in a Freeze Frame. The Freeze Frame is considered one frame of information taken by an on-board data recorder. When a fault occurs, the PCM stores the input data from various sensors so that technicians can determine under what vehicle operating conditions the failure occurred. The data stored in Freeze Frame is usually recorded when a system fails the first time for two trip faults. Freeze Frame data will only be overwritten by a different fault with a higher priority. CAUTION: Erasing DTCs, either with the DRBIIIT; or by disconnecting the battery, also clears all Freeze Frame data. Similar Conditions Window The Similar Conditions Window displays information about engine operation during a monitor. Absolute MAP (engine load) and Engine RPM are stored in this window when a failure occurs. There are two different Similar conditions Windows: Fuel System and Misfire. FUEL SYSTEM • Fuel System Similar Conditions Window — An indicator that ’Absolute MAP When Fuel Sys Fail’ and ’RPM When Fuel Sys Failed’ are all in the same range when the failure occurred. Indicated by switching from ’NO’ to ’YES’. • Absolute MAP When Fuel Sys Fail — The stored MAP reading at the time of failure. Informs the user at what engine load the failure occurred. • Absolute MAP — A live reading of engine load to aid the user in accessing the Similar Conditions Window. • RPM When Fuel Sys Fail — The stored RPM reading at the time of failure. Informs the user at what engine RPM the failure occurred. • Engine RPM — A live reading of engine RPM to aid the user in accessing the Similar Conditions Window. • Adaptive Memory Factor — The PCM utilizes both Short Term Compensation and Long Term Adaptive to calculate the Adaptive Memory Factor for total fuel correction. • Upstream O2S Volts — A live reading of the Oxygen Sensor to indicate its performance. For example, stuck lean, stuck rich, etc. • SCW Time in Window (Similar Conditions Window Time in Window) — A timer used by the PCM that indicates that, after all Similar Conditions have been met, if there has been enough good engine running time in the SCW without failure detected. This timer is used to increment a Good Trip. • Fuel System Good Trip Counter — A Trip Counter used to turn OFF the MIL for Fuel System DTCs. To increment a Fuel System Good Trip, the engine must be in the Similar Conditions Window, Adaptive Memory Factor must be less than calibrated threshold and the Adaptive Memory Factor must stay below that threshold for a calibrated amount of time. • Test Done This Trip — Indicates that the monitor has already been run and completed during the current trip. MISFIRE • Same Misfire Warm-Up State — Indicates if the misfire occurred when the engine was warmed up (above 160° F). • In Similar Misfire Window — An indicator that ’Absolute MAP When Misfire Occurred’ and ’RPM When Misfire Occurred’ are all in the same range when the failure occurred. Indicated by switching from ’NO’ to ’YES’. • Absolute MAP When Misfire Occurred — The stored MAP reading at the time of failure. Informs the user at what engine load the failure occurred. RS ON-BOARD DIAGNOSTICS 25 - 27 TASK MANAGER (Continued) • Absolute MAP — A live reading of engine load to aid the user in accessing the Similar Conditions Window. • RPM When Misfire Occurred — The stored RPM reading at the time of failure. Informs the user at what engine RPM the failure occurred. • Engine RPM — A live reading of engine RPM to aid the user in accessing the Similar Conditions Window. • Adaptive Memory Factor — The PCM utilizes both Short Term Compensation and Long Term Adap- tive to calculate the Adaptive Memory Factor for total fuel correction. • 200 Rev Counter — Counts 0–100 720 degree cycles. • SCW Cat 200 Rev Counter — Counts when in similar conditions. • SCW FTP 1000 Rev Counter — Counts 0–4 when in similar conditions. • Misfire Good Trip Counter — Counts up to three to turn OFF the MIL. EMISSIONS CONTROL 2.5L TURBO DIESEL RG 25a - 1 EMISSIONS CONTROL 2.5L TURBO DIESEL TABLE OF CONTENTS page page EMISSIONS CONTROL 2.5L TURBO DIESEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . . 2 EXHAUST GAS RECIRCULATION ............3 ON-BOARD DIAGNOSTICS .................6 EMISSIONS CONTROL 2.5L TURBO DIESEL Fuel Pressure: Fuel pressure is controlled by the fuel injection pump and fuel pressure solenoid. The ECM uses a fuel pressure sensor to determine if a fuel pressure problem exists. Fuel Injector Malfunctions: The ECM can determine if a fuel injector has an electrical problem. The fuel injectors on the diesel engine are controlled by the ECM. DESCRIPTION The 2.5L diesel Engine Control Module (ECM) controls many different circuits in the fuel injection pump and engine systems. If the ECM senses a problem with a monitored circuit that indicates an actual problem, a Diagnostic Trouble Code (DTC) will be stored in the ECM’s memory, and eventually may illuminate the MIL (Malfunction Indicator Lamp) constantly while the key is on. If the problem is repaired, or is intermittent, the ECM will erase the DTC after 40 warm-up cycles without the the fault detected. A warm-up cycle consists of starting the vehicle when the engine is cold, then the engine is warmed up to a certain temperature, and finally, the engine temperature falls to a normal operating temperature, then the key is turned off. Certain criteria must be met for a DTC to be entered into ECM memory. The criteria may be a specific range of engine rpm, engine or fuel temperature and/or input voltage to the ECM. A DTC indicates that the ECM has identified an abnormal signal in a circuit or the system. There are several operating conditions that the ECM does not monitor and set a DTC for. Refer to the following Monitored Circuits and Non–Monitored Circuits in this section. ECM MONITORED SYSTEMS The ECM can detect certain problems in the electrical system. Open or Shorted Circuit – The ECM will not distinguish between an open or a short to ground, however the ECM can determine if there is excessive current on a circuit, such as a short to voltage or a decrease in component resistance. Output Device Current Flow – The ECM senses whether the output devices are electrically connected. If there is a problem with the circuit, the ECM senses whether the circuit is open, shorted to ground (–), or shorted to (+) voltage. ECM NON–MONITORED SYSTEMS The ECM does not monitor the following circuits, systems or conditions that could have malfunctions that result in driveability problems. A DTC will not be displayed for these conditions. Cylinder Compression: The ECM cannot detect uneven, low, or high engine cylinder compression. Exhaust System: The ECM cannot detect a plugged, restricted or leaking exhaust system. Vacuum Assist: Leaks or restrictions in the vacuum circuits of the Exhaust Gas Recirculation System (EGR) are not monitored by the ECM. ECM System Ground: The ECM cannot determine a poor system ground. However, a DTC may be generated as a result of this condition. ECM/PCM Connector Engagement: The ECM cannot determine spread or damaged connector pins. However, a DTC may be generated as a result of this condition. HIGH AND LOW LIMITS The ECM compares input signals from each input device. It has high and low limits that are programmed into it for that device. If the inputs are not within specifications and other DTC criteria are met, a DTC will be stored in memory. Other DTC criteria might include engine rpm limits or input voltages from other sensors or switches. The other inputs might have to be sensed by the ECM when it senses a high or low input voltage from the control system device in question. 25a - 2 EMISSIONS CONTROL 2.5L TURBO DIESEL RG EMISSIONS CONTROL 2.5L TURBO DIESEL (Continued) SPECIFICATIONS - TORQUE 2.5L DIESEL - TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. EGR Cooler to EGR Bolts 32.4 24 — EGR Cooler to Exhaust Manifold 27.5 21 — EGR Valve Nuts 32.4 24 — EXHAUST GAS RECIRCULATION RG 25a - 3 EXHAUST GAS RECIRCULATION TABLE OF CONTENTS page EXHAUST GAS RECIRCULATION DESCRIPTION . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . VALVE DESCRIPTION . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . ..............3 ..............3 ..............3 ..............3 EXHAUST GAS RECIRCULATION DESCRIPTION The EGR system reduces oxides of nitrogen (NOx) in the engine exhaust. This is accomplished by allowing a predetermined amount of hot exhaust gas to recirculate and dilute the incoming fuel/air mixture. A malfunctioning EGR system can cause engine stumble, sags, or hesitation, rough idle, engine stalling and poor driveability. OPERATION The system consists of: • An EGR valve assembly. The valve is located on the rear of the engine above the exhaust manfiold. • An EGR solenoid.The EGR solenoid controls the “on time” of the EGR valve. • The ECM operates the EGR solenoid. The ECM is located inside the vehicle under the instrument panel. • An EGR tube connects a passage in the EGR valve to the rear of the exhaust manifold. • The vacuum pump supplies vacuum for the EGR solenoid and the EGR valve. This pump also supplies vacuum for operation of the power brake boosterb and the heating and air conditioning system. The pump is located internally in the front of the engine block and is driven by the crankshaft gear. page REMOVAL .. INSTALLATION VALVE COOLER DESCRIPTION REMOVAL .. INSTALLATION ...........................4 ..........................4 ..........................4 ...........................4 ..........................5 • Vacuum lines and hoses connect the various components. When the ECM supplies a variable ground signal to the EGR solenoid, EGR system operation starts to occur. The ECM will monitor and determine when to supply and remove this variable ground signal. This will depend on inputs from the engine coolant temperature, throttle position and engine speed sensors. When the variable ground signal is supplied to the EGR solenoid, vacuum from the vacuum pump will be allowed to pass through the EGR solenoid and on to the EGR valve with a connecting hose. Exhaust gas recirculation will begin in this order when: • The ECM determines that EGR system operation is necessary. • The engine is running to operate the vacuum pump. • A variable ground signal is supplied to the EGR solenoid. • Variable vacuum passes through the EGR solenoid to the EGR valve. • The inlet seat (poppet valve) at the bottom of the EGR valve opens to dilute and recirculate exhaust gas back into the intake manifold. The EGR system will be shut down by the ECM after 60 seconds of continuous engine idling to improve idle quality. 25a - 4 EXHAUST GAS RECIRCULATION RG VALVE DESCRIPTION The EGR system consists of (Fig. 1): • EGR valve • EGR tube • Vacuum hoses • EGR cooler • EGR solenoid OPERATION The engines use Exhaust Gas Recirculation (EGR) systems. The EGR system reduces oxides of nitrogen (NOx) in engine exhaust and helps prevent detonation (engine knock). Under normal operating conditions, engine cylinder temperature can reach more than 3000°F. Formation of NOx increases proportionally with combustion temperature. To reduce the emission of these oxides, the cylinder temperature must be lowered. The system allows a predetermined amount of hot exhaust gas to recirculate and dilute the incoming air/fuel mixture. The diluted air/fuel mixture reduces peak flame temperature during combustion. REMOVAL (1) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (2) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (3) Disconnect EGR valve vacuum line. (4) Remove EGR cooler to EGR valve retaining bolts (Fig. 1). (5) Remove EGR valve retaining nuts (Fig. 1) and EGR valve. INSTALLATION (1) Clean gasket mating surfaces. (2) Install EGR valve (Fig. 1). Torque nuts to 32.4N·m. (3) Connect EGR cooler to EGR valve (Fig. 1). Torque bolts to 32.4N·m (4) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (5) Install engine cover (Refer to 9 - ENGINE INSTALLATION). Fig. 1 EGR COMPONENTS 1 - HOSE CLAMP 2 - COOLANT HOSE 3 - HOSE CLAMP 4 - EGR VALVE RETAINING NUT 5 - EGR VALVE 6 - COOLANT HOSE 7 - EGR VALVE GASKET 8 - EGR VALVE RETAINING STUDS 9 - EGR COOLER RETAINING BOLT 10 - HOSE CLAMP 11 - HOSE CLAMP 12 - EGR COOLER 13 - EGR COOLER TO EGR VALVE RETAINING BOLT 14 - TURBOCHARGER BRACKET 15 - TURBOCHARGER BRACKET RETAINING BOLT 16 - TURBOCHARGER DOWNPIPE 17 - TURBOCHARGER DOWNPIPE RETAINING NUT 18 - DOWNPIPE GASKET 19 - DOWNPIPE STUD RG EXHAUST GAS RECIRCULATION VALVE COOLER DESCRIPTION The EGR valve on this engine uses a cooler to cool the exhaust gases before the returned to the intake manifold (Fig. 2). The EGR cooler attaches to the EGR valve and is cooled with engine coolant. REMOVAL (1) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (2) Partially drain cooling system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE). (3) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (4) Disconnect coolant supply and return lines at EGR cooler (Fig. 2). (5) Remove EGR cooler to exhaust manifold retaining bolt (Fig. 2). (6) Remove EGR cooler to EGR valve retaining bolts (Fig. 2) and remove cooler. INSTALLATION (1) Clean gasket sealing surfaces. (2) Connect EGR valve cooler and new gasket to EGR valve (Fig. 2). Torque bolts to 32.4N·m. (3) Install EGR valve cooler to exhaust manifold attaching bolt (Fig. 2). Torque bolt to 32.4N·m. (4) Connect EGR cooler coolant supply and return hoses to cooler (Fig. 2). (5) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (6) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (7) Install engine cover (Refer to 9 - ENGINE INSTALLATION). Fig. 2 EGR COMPONENTS 1 - HOSE CLAMP 2 - COOLANT HOSE 3 - HOSE CLAMP 4 - EGR VALVE RETAINING NUT 5 - EGR VALVE 6 - COOLANT HOSE 7 - EGR VALVE GASKET 8 - EGR VALVE RETAINING STUDS 9 - EGR COOLER RETAINING BOLT 10 - HOSE CLAMP 11 - HOSE CLAMP 12 - EGR COOLER 13 - EGR COOLER TO EGR VALVE RETAINING BOLT 14 - TURBOCHARGER BRACKET 15 - TURBOCHARGER BRACKET RETAINING BOLT 16 - TURBOCHARGER DOWNPIPE 17 - TURBOCHARGER DOWNPIPE RETAINING NUT 18 - DOWNPIPE GASKET 19 - DOWNPIPE STUD 25a - 5 25a - 6 ON-BOARD DIAGNOSTICS RG ON-BOARD DIAGNOSTICS TABLE OF CONTENTS page ON-BOARD DIAGNOSTICS DESCRIPTION - DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ON-BOARD DIAGNOSTICS DESCRIPTION - DIAGNOSTIC TROUBLE CODES On the following pages, a list of DTC’s is provided for the 2.5L diesel engine. A DTC indicates that the ECM has recognized an abnormal signal in a circuit or the system. A DTC may indicate the result of a failure, but most likely will not identify the failed component directly. Refer to the appropriate diagnostic manual for more information on diagnosis of trouble codes. ACCESSING DIAGNOSTIC TROUBLE CODES A stored DTC can be displayed through the use of the DRB IIIt scan tool. The DRB IIIt connects to the data link connector. The data link connector is located under the instrument panel near bottom of the steering column (Fig. 1). ERASING TROUBLE CODES After the problem has been repaired, use the DRB IIIt scan tool to erase a DTC. Fig. 1 DATA LINK CONNECTOR ON-BOARD DIAGNOSTICS RG ON-BOARD DIAGNOSTICS (Continued) ENGINE CONTROL MODULE (ECM) - DRBIIIT CODES Generic Scan Tool Code DRB IIIT Scan Tool Display P0070 Ambient Air Temperature Circuit Signal Voltage Too High Ambient Air Temperature Circuit Signal Voltage Too Low P0100 Mass Air Flow Sensor Plausibility Mass Air Flow Sensor Plausibility Positive Area Mass Air Flow Sensor Signal Voltage Too High Mass Air Flow Sensor Signal Voltage Too Low Mass Air Flow Sensor Supply Voltage Too High Or Low P0105 Barometric Pressure Circuit Signal Voltage To High Barometric Pressure Circuit Signal Voltage To Low P0110 Intake Air Temperature Sensor Circuit Signal Too High Intake Air Temperature Sensor Circuit Signal Too Low P0115 Engine Coolant Temperature Sensor Circuit Engine Is Cold Too Long Engine Coolant Temperature Sensor Circuit Voltage To Low Engine Coolant Temperature Sensor Circuit Voltage To High P0190 Fuel Pressure Sensor Circuit MALF Signal Voltage Too High Fuel Pressure Sensor Circuit MALF Signal Voltage Too Low P0195 Oil Temperature Sensor Circuit MALF Signal Voltage Too High Oil Temperature Sensor Circuit MALF Signal Voltage Too Low P0201 Cylinder 1 Injector Circuit Current Decrease Cylinder 1 Injector Circuit Load Drop Cylinder 1 Injector Circuit Overcurrent High Side Cylinder 1 Injector Circuit Overcurrent Low Side P0202 Cylinder 2 Injector Circuit Current Decrease Cylinder 2 Injector Circuit Load Drop Cylinder 2 Injector Circuit Overcurrent High Side Cylinder 2 Injector Circuit Overcurrent Low Side P0203 Cylinder 3 Injector Circuit Current Decrease Cylinder 3 Injector Circuit Load Drop Cylinder 3 Injector Circuit Overcurrent High Side Cylinder 3 Injector Circuit Overcurrent Low Side P0204 Cylinder 4 Injector Circuit Current Decrease Cylinder 4 Injector Circuit Load Drop Cylinder 4 Injector Circuit Overcurrent High Side Cylinder 4 Injector Circuit Overcurrent Low Side P0235 Boost Pressure Sensor Plausibility Boost Pressure Sensor Signal Voltage Too Low Boost Pressure Sensor Signal Voltage Too High 25a - 7 25a - 8 ON-BOARD DIAGNOSTICS ON-BOARD DIAGNOSTICS (Continued) Generic Scan Tool Code DRB IIIT Scan Tool Display Boost Pressure Sensor Signal Voltage Too High Or Low P0335 CKP Position Sensor Circuit Dynamic Plausibility CKP Position Sensor Circuit Overspeed Recognition CKP Position Sensor Circuit Static Plausibility P0340 CMP Position Sensor Circuit CMP/CKP Sync. Failure CMP Position Sensor Circuit Dynamic Plausibility CMP Position Sensor Circuit Fuel Shut-Off Activated CMP Position Sensor Circuit Signal Frequency Too High CMP Position Sensor Circuit Static Plausibility P0380 Glow Plug Circuit A Open Circuit Glow Plug Circuit A Short Circuit P0403 EGR Solenoid Circuit Open Circuit EGR Solenoid Circuit Short Circuit P0480 Fan 1 Control Circuit Open Circuit Fan 1 Control Circuit Short Circuit P0481 Fan 2 Control Circuit Open Circuit Fan 2 Control Circuit Short Circuit P0500 Vehicle Speed Sensor Frequency Too High Vehicle Speed Sensor Frequency High Level Duration Vehicle Speed Sensor Plausibility Vehicle Speed Sensor Signal Voltage Too High P0514 Battery Temperature Sensor Circuit Signal Voltage Too High P0520 Oil Pressure Sensor Circuit MALF Signal Voltage Too High Oil Pressure Sensor Circuit MALF Signal Voltage Too Low Oil Pressure Sensor Circuit MALF Signal Voltage Too Low or High P0530 A/C Pressure Sensor Circuit Plausibility A/C Pressure Sensor Circuit Signal Voltage Too High A/C Pressure Sensor Circuit Signal Voltage Too Low A/C Pressure Sensor Circuit Supply Voltage Too High Or Low P0560 System Voltage Too High System Voltage Too Low P0579 Speed Control Switch Signal Circuit Voltage Too High Speed Control Switch Signal Circuit Voltage Too Low P0606 ECM Error Gate Array - Communication ECM Error Gate Array - Communication Not Verified ECM Error Gate Array - Quantity Stop ECM Error Gate Array - Has Occurred RG ON-BOARD DIAGNOSTICS RG ON-BOARD DIAGNOSTICS (Continued) Generic Scan Tool Code DRB IIIT Scan Tool Display ECM Error Redundant Overrun Monitoring P0615 Starter Relay Circuit Open Circuit Starter Relay Circuit Short Circuit P0620 Generator Field Control MALF Open Circuit Generator Field Control MALF Short Circuit P0641 Sensor Reference Voltage A CKT Voltage Too High Sensor Reference Voltage A CKT Voltage Too Low P0645 A/C Clutch Relay Circuit Open Circuit A/C Clutch Relay Circuit Short Circuit P0651 Sensor Reference Voltage B CKT Voltage Too Low Sensor Reference Voltage B CKT Voltage Too High P0685 ECM/PCM Relay Control Circuit Shuts Off Too Early ECM/PCM Relay Control Circuit Shuts Off Too Late P0703 Brake Switch Signal Circuits Incorrect Can Message Brake Switch Signal Circuits Plausibility With Redundant Contact P1130 Fuel Rail Pressure Malfunction Small Leakage Detected Fuel Rail Pressure Malfunction Small Leakage Detected P1131 Fuel Pressure Solenoid Open Circuit Fuel Pressure Solenoid Short Circuit P1206 Calculated Injector Voltage #1 Too Low Calculated Injector Voltage #2 Too Low P1511 Battery Sense Line 1 Voltage Too High Battery Sense Line 1 Voltage Too Low P1601 Capacitor Voltage 1 Voltage Too High Capacitor Voltage 1 Voltage Too Low P1602 Capacitor Voltage 2 Voltage Too High Capacitor Voltage 2 Voltage Too Low P1605 Ignition Switch Plausibility P1610 Voltage Regulator Signal Voltage Too High Voltage Regulator Signal Voltage Too Low 25a - 9 25a - 10 ON-BOARD DIAGNOSTICS ON-BOARD DIAGNOSTICS (Continued) Generic Scan Tool Code DRB IIIT Scan Tool Display P1680 EEPROM Plausibility Checksum Error EEPROM Plausibility Code Word Incorrect Or Missing EEPROM Plausibility Communication Error EEPROM Plausibility Variation Number Error EEPROM Plausibility VIN Checksum Error EEPROM Plausibility VIN Write Error P1685 SKIM System Invalid Key Code Received SKIM System Invalid Secret Key In EEPROM SKIM System Key Communication Timed Out SKIM System SKIM Error SKIM System Write Access To EEPROM Failure P1696 EEPROM Communication Error EEPROM Communication Not Verified EEPROM Quanity Stop EEPROM Recovery Occured EEPROM Redundant Overrun Monitoring P1703 Brake Switch Signal CKTS Plaus. With Redundant Contact After Initialization P2120 Acc. Pedal Position Sensor 1 CKT Plausibility Acc. Pedal Position Sensor 1 CKT Plausibility With Brake Switch Acc. Pedal Position Sensor 1 CKT Plausibility With Potentiometer Acc. Pedal Position Sensor 1 CKT Signal Voltage Too High Acc. Pedal Position Sensor 1 CKT Signal Voltage Too Low Acc. Pedal Position Sensor 1 CKT Signal Voltage Too High or Low RG INSTRUMENT CLUSTER RS 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - SELFDIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . 2 DIAGNOSIS AND TESTING - CLUSTER DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 CLUSTER LENS REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . MECHANICAL TRANSMISSION RANGE INDICATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . RED BRAKE WARNING INDICATOR DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER The mechanical instrument cluster without a tachometer also has the following warning lamps: • Turns Signals • High Beam • Oil Pressure • Malfunction Indicator Lamp (MIL) DESCRIPTION The instrumentation gauges are contained in a subdial assembly within the instrument cluster. The individual gauges are not serviceable. If one of the cluster gauges becomes faulty, the entire cluster would require replacement. The mechanical instrument cluster with a tachometer is equipped with a electronic vacuum fluorescent transmission range indicator (PRND3L), odometer, and trip odometer display. The mechanical instrument cluster without a tachometer is equipped with a cable operated transmission range indicator (PRND21) and a vacuum fluorescent odometer display. It also has the following indicators: • Turn Signals • High Beam • Oil Pressure • MIL The instrument cluster is equipped with the following warning lamps. • Lift Gate Ajar • Low Fuel Level • Low Windshield Washer Fluid Level • Cruise • Battery Voltage • Fasten Seat Belt • Door Ajar • Coolant Temperature • Anti-Lock Brake • Brake • Airbag • Traction Control • Autostick . . . . . . . . 12 . . . . . . . . 12 . . . . . . . . 12 . . . . . . . . 12 . . . . . . . . 13 . . . . . . . . 13 WATER IN FUEL LAMP - EXPORT The Water In Fuel Lamp is located in the instrument cluster. When moisture is found within the fuel system, the sensor sends a message via the PCI data bus to the instrument cluster. The sensor is located underneath the vehicle, directly above the rear axle. The sensor is housed within the fuel filter/water separator assembly cover. The sensor is not serviced separately. If found defective, the entire assembly cover must be replaced. OPERATION Refer to the vehicle Owner’s Manual for operation instructions and conditions for the Instrument Cluster Gauges. WATER IN FUEL LAMP - EXPORT The Water In Fuel Sensor is a resistive type switch. It is calibrated to sense the different resistance between diesel fuel and water. When water enters the fuel system, it is caught in the bottom of the fuel filter/water separator assembly, where the sensor is located. Water has less resistance than diesel fuel. The sensor then sends a PCI data bus message to the instrument cluster to illuminate the lamp. If the lamp is inoperative, perform the self diagnostic test on the instrument cluster to check the lamp operation before continuing diagnosis. 8J - 2 INSTRUMENT CLUSTER RS INSTRUMENT CLUSTER (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - SELFDIAGNOSTICS The instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self-Diagnostic Test. The self diagnostic system displays instrument cluster stored fault codes in the odometer display, sweeps the gauges to the calibration points, and bulb checks the warning indicators. When the key is in the ON position with the engine not running, the MIL will remain illuminated for regulatory purposes. To activate the Self-Diagnostic program: (1) With the ignition switch in the OFF position, depress the TRIP ODOMETER RESET button. (2) Continue to hold the TRIP ODOMETER RESET button until Sof and a number (software version number (i.e. Sof 3.2) appears in the odometer window then release the button. If a fault code is present, the cluster will display it in the odometer display. When all fault codes have been displayed, the cluster will display “end” in the odometer display. Refer to the INSTRUMENT CLUSTER DTC’S table to determine what each trouble code means. INSTRUMENT CLUSTER DTC’S DTC DESCRIPTION 100.0 LOOP-BACK FAILURE 100.1 ABS COMMUNICATION FAULT 100.2 BCM COMMUNICATION FAULT 100.3 EATX COMMUNICATION FAULT 100.4 FCM COMMUNICATION FAULT 100.5 ORC COMMUNICATION FAULT 100.6 SBEC/DEC/MCM COMMUNICATION FAULT 200.0 AIRBAG LED SHORT 200.1 AIRBAG LED OPEN 200.2 ABS LED SHORT 200.3 ABS LED OPEN 200.6 EL INVERTER TIME-OUT 200.7 EATX MISMATCH CALIBRATION TEST The CLUSTER CALIBRATION table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration, replace the cluster. CLUSTER CALIBRATION SPEEDOMETER CALIBRATION POINT 1 0 MPH (0 KM/H) 2 20 MPH (40 KM/H) 3 60 MPH (100 KM/H) 4 100 MPH (160 KM/H) TACHOMETER 1 0 RPM 2 1000 RPM 3 3000 RPM 4 6000 RPM FUEL GAUGE 1 EMPTY 2 1/4 FILLED 3 1/2 FILLED 4 FULL TEMPERATURE GAUGE 1 COLD 2 1/4 3 3/4 4 HOT ODOMETER SEGMENT TEST If a segment in the odometer does not illuminate normally, a problem exists in the display. ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display. DIAGNOSIS AND TESTING - CLUSTER DIAGNOSIS CONDITIONS Refer to the following tables for possible problems, causes, and corrections. • INSTRUMENT CLUSTER DIAGNOSIS • SPEEDOMETER DIAGNOSIS • TACHOMETER DIAGNOSIS • FUEL GAUGE DIAGNOSIS • TEMPERATURE GAUGE DIAGNOSIS • ODOMETER DIAGNOSIS • ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS • MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS INSTRUMENT CLUSTER RS 8J - 3 INSTRUMENT CLUSTER (Continued) NOTE: Always check the functionality of the cluster by running the self test prior to troubleshooting. INSTRUMENT CLUSTER DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION INSTRUMENT CLUSTER INOPERATIVE. NO RESPONSE FROM INSTRUMENT CLUSTER. NO PCI BUS MESSAGES FROM THE BCM. USE A DRB IIIT SCAN TOOL TO CHECK THE BCM. IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE FOR CLUSTER FAILURE. IF NOT OK, REFER TO THE PROPER BODY DIAGNOSTIC PROCEDURES MANUAL. SPREAD TERMINAL(S) ON WIRING HARNESS CLUSTER CONNECTOR. REMOVE CLUSTER FROM INSTRUMENT PANEL AND CHECK WIRING HARNESS CONNECTOR FOR SPREAD TERMINAL. IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE FOR THE CLUSTER FAILURE. IF NOT OK, REPAIR CONNECTOR. BCM IS NOT RECEIVING PROPER INPUT FROM THE IGNITION SWITCH. 1. USE A DRB IIIT SCAN TOOL TO VERIFY IGNITION SWITCH STATUS INTO THE BCM. IF NOT OK, GO TO STEP (2). IF OK, LOOK AT ANOTHER POSSIBLE CAUSE OF FAILURE. 2. CHECK IGNITION SWITCH FUNCTION AND WIRING. INTERNAL CLUSTER FAILURE. REPLACE CLUSTER. WAKE UP CIRCUIT FAULTY. VERIFY CONTINUITY OF WAKE UP CIRCUIT FROM BCM TO MIC. CIRCUIT SHALL BE LOW WHENEVER BCM IS AWAKE. POWER OR GROUND MISSING. IF NO RESPONSE FROM THE MIC, CHECK FOR POWER AND GROUND AT THE MIC CONNECTOR. REFER TO WIRING DIAGRAMS FOR CONNECTOR CALL OUTS. 8J - 4 INSTRUMENT CLUSTER RS INSTRUMENT CLUSTER (Continued) SPEEDOMETER DIAGNOSIS CONDITION NO POINTER MOVEMENT. POSSIBLE CAUSES 1. INTERNAL CLUSTER FAILURE. CORRECTION 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF SPEEDOMETER POINTER MOVES TO CALIBRATION POINTS DURING TEST LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. • IF THE POINTER DOESN’T MOVE DURING TEST, CHECK FOR POWER AND GROUND TO THE MIC. IF POWER AND GROUND ARE PRESENT GO TO STEP 1.B. 1.B. REPLACE CLUSTER. GO TO STEP 1.C. 1.C. CONNECT CLUSTER INTO INSTRUMENT PANEL WIRING HARNESS. PLACE IT BACK INTO THE PROPER POSITION IN THE INSTRUMENT PANEL. PUT IN THE TOP FOUR MOUNTING SCREWS AND SECURE THE CLUSTER TO THE INSTRUMENT PANEL. 2. NO SPEED PCI BUS MESSAGE OR ZERO MPH PCI SPEED BUS MESSAGE. 2.A. CHECK THE PCM (CODE 10) USING A DRB IIIT SCAN TOOL. IF OK, GO TO STEP 2.B. IF NOT OK, REFER TO THE PROPER POWERTRAIN DIAGNOSTIC PROCEDURES MANUAL TO REPAIR THE PCM. 2.B. CHECK THE SPEED SIGNAL INPUT INTO THE PCM. THE SPEED SIGNAL ORIGINATES FROM ONE OF THE FOLLOWING SOURCES: • A DISTANCE SENSOR FOR VEHICLES WITH 3 SPEED AUTOMATIC TRANSMISSION. CHECK CONTINUITY FROM DISTANCE SENSOR TO PCM. IF OK, REPLACE DISTANCE SENSOR. IF NOT OK, REPAIR WIRING. • THE TCM FOR VEHICLES WITH THE 4 SPEED ELECTRONIC TRANSMISSIONS. CHECK CONTINUITY FROM TCM TO PCM. IF OK, USE A DRB IIIT SCAN TOOL TO CHECK TCM. REFER TO THE PROPER TRANSMISSION DIAGNOSTIC PROCEDURES MANUAL TO REPAIR THE TCM. IF NOT OK, REPAIR WIRING. INSTRUMENT CLUSTER RS 8J - 5 INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES ERRATIC POINTER MOVEMENT. 1. ERRATIC MESSAGE FROM ANOTHER MODULE. CORRECTION 1.A. CHECK THE BCM USING A DRB IIIT SCAN TOOL IF OK, GO TO STEP 1.B. IF NOT OK, REFER TO THE PROPER BODY DIAGNOSTIC PROCEDURES MANUAL TO REPAIR THE BCM. 1.B. CHECK THE PCM USING A DRB IIIT SCAN TOOL. IF OK, GO TO STEP 1.C. IF NOT OK, REFER TO THE PROPER POWERTRAIN DIAGNOSTIC PROCEDURES MANUAL TO REPAIR THE PCM. 1.C. CHECK THE SPEED SIGNAL INPUT INTO THE PCM. THE SPEED SIGNAL ORIGINATES FROM ONE OF THE FOLLOWING SOURCES: • A DISTANCE SENSOR FOR VEHICLES WITH 3 SPEED AUTOMATIC TRANSMISSION. CHECK CONTINUITY FROM DISTANCE SENSOR TO PCM. IF OK, REPLACE DISTANCE SENSOR. IF NOT OK, REPAIR WIRING. • THE TCM FOR VEHICLES WITH THE 4 SPEED ELECTRONIC TRANSMISSIONS. CHECK CONTINUITY FROM TCM TO PCM. IF OK, USE A DRB IIIT SCAN TOOL TO CHECK TCM. REFER TO THE PROPER TRANSMISSION DIAGNOSTIC PROCEDURES MANUAL TO REPAIR THE TCM. IF NOT OK, REPAIR WIRING. 2. INTERNAL CLUSTER FAILURE. 2.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF THE POINTER MOVES DURING TEST BUT STILL APPEARS ERRATIC, THEN GO TO STEP 2.B. 2.B. REPLACE CLUSTER ASSEMBLY. 8J - 6 INSTRUMENT CLUSTER RS INSTRUMENT CLUSTER (Continued) CONDITION SPEEDOMETER INACCURATE. POSSIBLE CAUSES CORRECTION 1. SPEEDOMETER OUT OF CALIBRATION. 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. • IF SPEEDOMETER IS ACCURATE TO THE CALIBRATION POINTS THEN LOOK FOR ANOTHER POSSIBLE CAUSE OF INACCURACY. • IF SPEEDOMETER IS NOT ACCURATE TO THE CALIBRATION POINTS, REPLACE CLUSTER ASSEMBLY. 2. WRONG SPEEDOMETER PINION FOR TIRE SIZE. 2.A. IF VEHICLE HAS A 4 SPEED ELECTRONIC TRANSMISSION GO TO STEP 2.C. OTHERWISE GO TO STEP 2.B. 2.B. CHECK IF CORRECT SPEEDOMETER PINION IS BEING USED WITH TIRES ON VEHICLE. REFER TO TRANSMISSION FOR DIAGNOSIS AND TESTING. • IF THE INCORRECT PINION IS IN TRANSMISSION THEN REPLACE WITH CORRECT PINION. • IF THE CORRECT PINION IS IN THE TRANSMISSION, CHECK TIRE SIZE. 2.C. USE A DRB IIIT SCAN TOOL TO CHECK THE TCM TO SEE IF THE CORRECT TIRE SIZE HAS BEEN PROGRAMMED INTO THE TCM. • IF THE INCORRECT TIRE SIZE WAS SELECTED, SELECT THE PROPER TIRE SIZE. • IF THE CORRECT TIRE SIZE WAS SELECTED, CHECK SPEED SENSOR. 3. BAD SPEED SENSOR. 3. REFER TO TRANSMISSION, SPEED SENSOR, DIAGNOSIS AND TESTING. TACHOMETER DIAGNOSIS CONDITION NO POINTER MOVEMENT. POSSIBLE CAUSES 1. INTERNAL CLUSTER FAILURE. CORRECTION 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF TACHOMETER POINTER MOVES TO CALIBRATION POINTS DURING TEST, LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. • IF THE POINTER DOESN’T MOVE DURING TEST, CHECK FOR POWER AND GROUND TO THE MIC. IF POWER AND GROUND ARE PRESENT GO TO STEP 1.B. 1.B. REPLACE CLUSTER. GO TO STEP 1.C. 2. 9NO RPM9 PCI BUS MESSAGE OR 9ZERO RPM9 PCI BUS MESSAGE FROM PCM. 2. CHECK THE PCM USING A DRB IIIT SCAN TOOL. REFER TO THE PROPER POWERTRAIN DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. INSTRUMENT CLUSTER RS 8J - 7 INSTRUMENT CLUSTER (Continued) CONDITION ERRATIC POINTER MOVEMENT. POSSIBLE CAUSES CORRECTION 1. BAD PCI BUS MESSAGE FROM PCM. 1. CHECK THE PCM USING A DRB IIIT SCAN TOOL. REFER TO THE PROPER POWERTRAIN DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. 2. INTERNAL CLUSTER FAILURE. 2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF THE POINTER MOVES DURING TEST BUT STILL APPEARS ERRATIC, REPLACE CLUSTER ASSEMBLY. TACHOMETER INACCURATE. TACHOMETER OUT OF CALIBRATION. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. • IF TACHOMETER IS ACCURATE TO THE CALIBRATION POINTS, LOOK FOR ANOTHER POSSIBLE CAUSE OF INACCURACY. • IF TACHOMETER IS NOT ACCURATE TO THE CALIBRATION POINTS, REPLACE CLUSTER ASSEMBLY. FUEL GAUGE DIAGNOSIS CONDITION NO POINTER MOVEMENT. POSSIBLE CAUSES 1. INTERNAL CLUSTER FAILURE. CORRECTION 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. • IF FUEL GAUGE POINTER MOVES TO CALIBRATION POINTS, LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. • IF THE POINTER DOESN’T MOVE DURING TEST, VERIFY POWER AND GROUND ARE BEING PROVIDED TO THE CLUSTER. IF YES, REPLACE CLUSTER ASSEMBLY. IF NO, DETERMINE CAUSE OF NO POWER OR GROUND. 2. NO PCI FUEL MESSAGE OR EMPTY PCI BUS MESSAGE FROM BODY CONTROL MODULE. 2.A. CHECK THE BCM USING A DRB IIIT SCAN TOOL. IF OK, GO TO STEP 2.B. IF NOT OK, REFER TO THE PROPER BODY DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. 2.B. REFER TO THE FUEL SECTION OF THE SERVICE MANUAL FOR THE FUEL LEVEL SENDING UNIT TEST PROCEDURE. TEST UNIT AND REPAIR AS INSTRUCTED. 8J - 8 INSTRUMENT CLUSTER RS INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES ERRATIC POINTER MOVEMENT. 1. BAD PCI FUEL MESSAGE FROM THE BODY CONTROLLER. CORRECTION 1. USE A DRB IIIT SCAN TOOL TO CHECK THE BCM. IF OK, GO TO STEP 2. IF NOT OK, REFER TO THE PROPER BODY DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. 2. REFER TO THE FUEL SECTION OF THE SERVICE MANUAL FOR THE FUEL LEVEL SENDING UNIT TEST PROCEDURE. TEST UNIT. IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE FOR FUEL GAUGE FAILURE. IF NOT OK, REPAIR SENDING UNIT. 2. INTERNAL CLUSTER FAILURE. 2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF THE POINTER MOVES DURING TEST BUT STILL APPEARS ERRATIC, REPLACE CLUSTER ASSEMBLY. FUEL GAUGE INACCURATE. 1. FUEL GAUGE OUT OF CALIBRATION. 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. IF POINTER IS ACCURATE TO THE CALIBRATION POINTS LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. IF POINTER IS INACCURATE TO THE CALIBRATION POINTS, REPLACE CLUSTER ASSEMBLY. 2. FUEL LEVEL SENDING UNIT IS OUT OF CALIBRATION. 2. REFER TO THE FUEL SECTION OF THE SERVICE MANUAL FOR TESTING AND REPAIR PROCEDURE. TEMPERATURE GAUGE DIAGNOSIS CONDITION NO POINTER MOVEMENT. POSSIBLE CAUSES 1. INTERNAL CLUSTER FAILURE. CORRECTION 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK. • IF TEMPERATURE GAUGE POINTER MOVES TO CALIBRATION POINTS, LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. • IF THE POINTER DOESN’T MOVE DURING TEST, VERIFY POWER AND GROUND ARE BEING PROVIDED TO THE CLUSTER. IF YES, REPLACE CLUSTER. IF NO, DETERMINE CAUSE OF NO POWER OR NO GROUND. 2. NO PCI TEMPERATURE MESSAGE OR COLD PCI BUS MESSAGE FROM THE POWERTRAIN CONTROL MODULE. 2.A. CHECK PCM FAULT CODES USING A DRB IIIT SCAN TOOL. IF THERE ARE NO FAULTS, GO TO STEP 2.B. IF THERE ARE FAULTS, REFER TO THE PROPER POWERTRAIN DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. 2.B. REFER TO FUEL, COOLANT TEMPERATURE SENSOR, DIAGNOSIS AND TESTING. REPAIR SENSOR AS NEEDED. INSTRUMENT CLUSTER RS 8J - 9 INSTRUMENT CLUSTER (Continued) CONDITION ERRATIC POINTER MOVEMENT. POSSIBLE CAUSES CORRECTION 1. BAD PCI BUS MESSAGE FROM THE POWERTRAIN CONTROL MODULE. 1.A. CHECK PCM FAULT CODES USING A DRB IIIT SCAN TOOL. IF THERE ARE NO FAULTS, GO TO STEP 1.B. IF THERE ARE FAULTS, REFER TO THE PROPER POWERTRAIN DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. 1.B. REFER TO FUEL, COOLANT TEMPERATURE SENSOR, DIAGNOSIS AND TESTING. REPAIR SENSOR AS NEEDED. 2. INTERNAL CLUSTER FAILURE. 2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF THE POINTER MOVES DURING TEST BUT STILL APPEARS ERRATIC, REPLACE CLUSTER ASSEMBLY. TEMPERATURE GAUGE INACCURATE. 1. TEMPERATURE GAUGE OUT OF CALIBRATION. 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. • IF POINTER IS ACCURATE TO THE CALIBRATION POINTS LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. • IF POINTER IS INACCURATE TO THE CALIBRATION POINTS, REPLACE CLUSTER ASSEMBLY. 2. COOLANT SENSOR OUT OF CALIBRATION. 2. REFER TO FUEL, COOLANT TEMPERATURE SENSOR FOR TEST AND REPAIR PROCEDURE. ODOMETER DIAGNOSIS CONDITION NO DISPLAY. POSSIBLE CAUSES CORRECTION 1. NO PCI BUS ODOMETER MESSAGE FROM BCM. 1. USE A DRB IIIT SCAN TOOL TO CHECK THE BCM. REFER TO THE PROPER BODY DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. 2. INTERNAL CLUSTER FAILURE. 2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF ODOMETER PASSES THE SEGMENT CHECK, LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. IF IT FAILS VERIFY POWER AND GROUND ARE BEING PROVIDED TO THE CLUSTER. IF YES, REPLACE CLUSTER. IF NO, DETERMINE CAUSE OF NO POWER OR GROUND. 8J - 10 INSTRUMENT CLUSTER RS INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES ERRATIC DISPLAY 1. INTERNAL CLUSTER FAILURE. CORRECTION 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF ODOMETER PASSES THE SEGMENT TEST, FAILURE MAY NOT BE IN THE CLUSTER. LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. 2. VERIFY GOOD POWER AND GROUND CONNECTIONS. IF CONNECTIONS ARE GOOD AND NO OTHER PROBLEMS ARE FOUND, REPLACE CLUSTER ASSEMBLY. 2. BAD PCI BUS MESSAGE FROM THE BCM. 2. USE A DRB IIIT SCAN TOOL TO CHECK THE BCM. REFER TO THE PROPER BODY DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. ODOMETER WON’T GO INTO TRIP MODE. TRIP SWITCH DOESN’T WORK. IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC MODE AND CANNOT TOGGLE BETWEEN ODOMETER AND TRIP ODOMETER, REPLACE CLUSTER. TRIP ODOMETER WON’T RESET. RESET SWITCH DOESN’T WORK. IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC MODE AND TRIP ODOMETER WILL NOT RESET, REPLACE CLUSTER. ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS CONDITION NO DISPLAY. POSSIBLE CAUSES 1. INTERNAL CLUSTER FAILURE. CORRECTION 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED) PASSES THE SEGMENT CHECK, THEN FAILURE MAY NOT BE IN THE CLUSTER. LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. IF IT FAILS, REPLACE CLUSTER ASSEMBLY. ERRATIC DISPLAY. 1. INTERNAL CLUSTER FAILURE. 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND CHECK FOR FAULT CODES. • IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED) PASSES THE SEGMENT CHECK, THEN FAILURE MAY NOT BE IN THE CLUSTER. LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE. 2. BAD PCI BUS MESSAGE FROM THE TCM. 2. USE A DRB IIIT SCAN TOOL TO CHECK THE TCM. REFER TO THE PROPER TRANSMISSION DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. INSTRUMENT CLUSTER RS 8J - 11 INSTRUMENT CLUSTER (Continued) CONDITION ALL SEGMENTS ARE ON. POSSIBLE CAUSES 1. NO PCI BUS MESSAGE FROM THE TCM. CORRECTION 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED) PASSES TEST GO TO STEP 1.B. IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED) FAILS TEST, REPLACE CLUSTER ASSEMBLY. 1.B. CHECK THE TCM USING A DRB IIIT SCAN TOOL. REFER TO THE PROPER TRANSMISSION DIAGNOSTIC PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR. MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS CONDITION INDICATOR DOES NOT SHOW PROPER GEAR OR NO INDICATION. POSSIBLE CAUSES MIS-ADJUSTED. CORRECTION 1.A. VERIFY TRANSMISSION SHIFT SYSTEM IS CORRECTLY ADJUSTED. 1.B. VERIFY CORRECT ROUTING AND ATTACHMENT OF PRNDL CABLE AND GUIDE TUBE. 1.C. RE-ADJUST PRNDL INDICATOR IN NEUTRAL USING ADJUSTER WHEEL BELOW STEERING COLUMN. INDICATOR DOES NOT FOLLOW GEAR SHIFT LEVER. NOT ATTACHED. 1.A. VERIFY INDICATOR CABLE CONNECTED TO SHIFT LEVER PIN IN THE GROOVE. INDICATOR DOES NOT MAKE FULL TRAVEL (“P” < > “1”). 1. CABLE DISLODGED FROM ITS PATH ON THE INDICATOR BASE. 1. VERIFY CORRECT ATTACHMENT OF INDICATOR CABLE TO SHIFT LEVER PIN (UNDER HOOP OF TRANS. SHIFT CABLE) AND CLIP ONTO THE MOUNTING BRACKET. 2. INCORRECT ATTACHMENT OF CABLE TO SHIFT LEVER PIN. 2. VERIFY INDICATOR TRAVEL BY PULLING ON CABLE GENTLY OVER FULL TRAVEL RANGE. IF THERE IS STILL A PROBLEM, REMOVE CLUSTER TO ACCESS INDICATOR BASE AND CONFIRM CABLE PATH. 1.B. VERIFY THAT THE INDICATOR CLIP IS SECURE, AND ATTACHED TO THE MOUNTING BRACKET. MAKE SURE THAT THE CLIP IS NOT BROKEN. IF THE CLIP IS BROKEN, REPLACE CLIP ON INDICATOR. REMOVAL WITH ELECTRONIC TRANSMISSION RANGE INDICATOR (1) Disconnect and isolate the battery negative cable. (2) Remove Over Steering Column Bezel by lifting it straight up with a firm pull. (3) Remove the four cluster bezel attaching screws. (4) Tilt the steering column in the full down position. (5) Pull rearward on the cluster bezel and remove. (6) Remove the four screws holding instrument cluster to instrument panel. (7) Rotate top of cluster outward. (8) Disconnect the cluster harness connector. (9) Remove instrument cluster from instrument panel. WITH MECHANICAL TRANSMISSION RANGE INDICATOR (1) Disconnect and isolate the battery negative cable. (2) Remove the lower steering column cover. Refer to Body, Instrument Panel, Lower Steering Column Cover, Removal. 8J - 12 INSTRUMENT CLUSTER RS INSTRUMENT CLUSTER (Continued) (3) Remove the plastic knee blocker reinforcement. Refer to Body, Instrument Panel, Knee Blocker Reinforcement, Removal. (4) Disconnect the transmission range indicator cable end from shift lever by flexing the HOOP on the transmission shift cable rearward and slip the indicator cable loop off the lever pin. (5) Disconnect the clip holding the indicator cable to the mounting bracket. (6) Remove Over Steering Column Bezel by lifting it straight up with a firm pull. (7) Remove the four bezel attaching screws. (8) Tilt the steering column in the full down position. (9) Pull rearward on the cluster bezel and remove. (10) Remove the four cluster attaching screws. (11) Rotate top of the cluster rearward. (12) Disconnect the cluster harness connector. (13) Remove the instrument cluster carefully while guiding the range indicator cable and guide tube through the opening to avoid any damage. INSTALLATION WITH ELECTRONIC TRANSMISSION RANGE INDICATOR (1) Connect the instrument cluster wire connector. (2) Rotate top of cluster inward as placing into instrument panel opening. (3) Install the four screws holding instrument cluster to instrument panel. (4) Position cluster bezel into place. (5) Install the four bezel attaching screws. (6) Install the Over Steering Column Bezel by firmly snapping into place. (7) Connect the battery negative cable. WITH MECHANICAL TRANSMISSION RANGE INDICATOR (1) Guide the range indicator cable and guide tube through the opening of instrument panel. (2) Connect the instrument cluster wire connector. (3) Rotate top of cluster inward as placing into instrument panel opening. (4) Install the four screws holding instrument cluster to instrument panel. (5) Position cluster bezel into place. (6) Install the four bezel attaching screws. (7) Install the Over Steering Column Bezel by firmly snapping into place. (8) Connect the clip holding the indicator cable to the mounting bracket. (9) Connect the transmission range indicator cable end to the shift lever by flexing the HOOP on the transmission shift cable forward and slip the indicator cable loop on the lever pin. (10) Install the plastic knee blocker reinforcement. Refer to Body, Instrument Panel, Knee Blocker Reinforcement, Installation. (11) Install the lower steering column cover. Refer to Body, Instrument Panel, Lower Steering Column Cover, Installation. (12) Connect the battery negative cable. CLUSTER LENS REMOVAL (1) Remove the instrument cluster. Refer to Electrical, Instrument Cluster, Removal. (2) Remove the screws holding the lens to the instrument cluster. (3) Press down on the snap features of the lens and remove the lens from the cluster. INSTALLATION (1) Insert the lens snap features into the cluster. (2) Install the screws holding the lens to the instrument cluster. (3) Install the instrument cluster. Refer to Electrical, Instrument Cluster, Installation. MECHANICAL TRANSMISSION RANGE INDICATOR REMOVAL (1) Remove the instrument cluster and disconnect the range indicator cable at both attaching points. Refer to Electrical, Instrument Cluster, Removal. (2) From the backside of the cluster, remove two screws holding the mechanical transmission range indicator and then remove it fromt instrument cluster. INSTALLATION (1) Insert the mechanical transmission range indicator into the backside of the instrument cluster and install the two screws. (2) Install the instrument cluster. Refer to Electrical, Instrument Cluster, Installation. INSTRUMENT CLUSTER RS RED BRAKE WARNING INDICATOR DESCRIPTION The red BRAKE warning indicator (lamp) is located in the instrument panel cluster and is used to indicate a low brake fluid condition or that the parking brake is applied. In addition, the brake warning indicator is turned on as a bulb check by the ignition switch every time the ignition switch is placed in the crank position. 8J - 13 OPERATION The red BRAKE warning indicator (lamp) is supplied a 12-volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the switch on the parking brake lever, the brake fluid level switch in the master cylinder reservoir, or the ignition switch when it is placed in the crank position. ENGINE SYSTEMS RS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 BATTERY SYSTEM TABLE OF CONTENTS page page BATTERY SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DIAGNOSIS AND TESTING - BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS . . . . . . . 7 BATTERY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING - BATTERY . . . . . . . 9 STANDARD PROCEDURE STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING . . . . . . . . . . . . . . . . . . 10 STANDARD PROCEDURE CONVENTIONAL BATTERY CHARGING. . . . . 11 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 13 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 13 STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL . . . . . . . . . 14 REMOVAL - BATTERY ........... INSTALLATION . . . . . . . . . . . . . . . . . BATTERY HOLDDOWN DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BATTERY CABLES DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BATTERY TRAY DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . THERMOWRAP DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BATTERY SYSTEM the following related components, which are covered in further detail elsewhere in this service manual: • Battery - The storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle. • Battery Cable - The battery cables connect the battery terminal posts to the vehicle electrical system. DESCRIPTION A single 12-volt battery system is standard factoryinstalled equipment on this model. All of the components of the battery system are located within the engine compartment of the vehicle. The service information for the battery system in this vehicle covers . . . . . . . . 14 . . . . . . . . 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . 15 . 15 . 16 ...... ...... CABLE ...... ...... . . 16 . . 16 . 16 . . 18 . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . 19 . 19 . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . 20 . 20 . 20 8F - 2 BATTERY SYSTEM RS BATTERY SYSTEM (Continued) • Battery Holddown - The battery holddown hardware secures the battery in the battery tray in the engine compartment. • Battery Thermowrap - The battery thermowarp insulates the battery to protect it from engine compartment temperature extremes. • Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor point for the battery holddown hardware. For battery system maintenance schedules and jump starting procedures, see the owner’s manual in the vehicle glove box. Optionally, refer to Lubrication and Maintenance for the recommended battery maintenance schedules and for the proper battery jump starting procedures. While battery charging can be considered a maintenance procedure, the battery charging procedures and related information are located in the standard procedures section of this service manual. This was done because the battery must be fully-charged before any battery system diagnosis or testing procedures can be performed. Refer to Standard procedures for the proper battery charging procedures. OPERATION The battery system is designed to provide a safe, efficient, reliable and mobile means of delivering and storing electrical energy. This electrical energy is required to operate the engine starting system, as well as to operate many of the other vehicle accessory systems for limited durations while the engine and/or the charging system are not operating. The battery system is also designed to provide a reserve of electrical energy to supplement the charging system for short durations while the engine is running and the electrical current demands of the vehicle exceed the output of the charging system. In addition to delivering, and storing electrical energy for the vehicle, the battery system serves as a capacitor and voltage stabilizer for the vehicle electrical system. It absorbs most abnormal or transient voltages caused by the switching of any of the electrical components or circuits in the vehicle. DIAGNOSIS AND TESTING - BATTERY SYSTEM The battery, starting, and charging systems in the vehicle operate with one another and must be tested as a complete system. In order for the engine to start and the battery to maintain its charge properly, all of the components that are used in these systems must perform within specifications. It is important that the battery, starting, and charging systems be thoroughly tested and inspected any time a battery needs to be charged or replaced. The cause of abnormal battery discharge, overcharging or early battery failure must be diagnosed and corrected before a battery is replaced and before a vehicle is returned to service. The service information for these systems has been separated within this service manual to make it easier to locate the specific information you are seeking. However, when attempting to diagnose any of these systems, it is important that you keep their interdependency in mind. The diagnostic procedures used for the battery, starting, and charging systems include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an induction-type milliampere ammeter, a volt/ohmmeter, a battery charger, a carbon pile rheostat (load tester) and a 12-volt test lamp may be required. All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. Refer to Charging System for the proper charging system onboard diagnostic test procedures. MICRO 420 ELECTRICAL SYSTEM TESTER The Micro 420 automotive battery system tester is designed to help the dealership technicians diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction manual is not available refer to the standard procedure in this section, which includes the directions for using the Micro 420 electrical system tester. BATTERY SYSTEM RS 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION THE BATTERY SEEMS WEAK OR DEAD WHEN ATTEMPTING TO START THE ENGINE. POSSIBLE CAUSES CORRECTION 1. The electrical system ignition-off draw is excessive. 1. Refer to the IGNITION-OFF DRAW TEST Standard Procedure for the proper test procedures. Repair the excessive ignition-off draw, as required. 2. The charging system is faulty. 2. Determine if the charging system is performing to specifications. Refer to Charging System for additional charging system diagnosis and testing procedures. Repair the faulty charging system, as required. 3. The battery is discharged. 3. Determine the battery state-of-charge using the Micro 420 battery tester. Refer to the Standard Procedures in this section for additional test procedures. Charge the faulty battery, as required. 4. The battery terminal connections are loose or corroded. 4. Refer to Battery Cables for the proper battery cable diagnosis and testing procedures. Clean and tighten the battery terminal connections, as required. 5. The battery has an incorrect size or rating for this vehicle. 5. Refer to Battery System Specifications for the proper size and rating. Replace an incorrect battery, as required. 6. The battery is faulty. 6. Test the battery using the Micro 420 battery tester. Refer to the Standard Procedures in this section for additional test procedures. Replace the faulty battery, as required. 7. The starting system is faulty. 7. Determine if the starting system is performing to specifications. Refer to Starting System for the proper starting system diagnosis and testing procedures. Repair the faulty starting system, as required. 8. The battery is physically damaged. 8. Inspect the battery for loose terminal posts or a cracked and leaking case. Replace the damaged battery, as required. 8F - 4 BATTERY SYSTEM RS BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION THE BATTERY STATE OF CHARGE CANNOT BE MAINTAINED. THE BATTERY WILL NOT ACCEPT A CHARGE. POSSIBLE CAUSES CORRECTION 1. The battery has an incorrect size or rating for this vehicle. 1. Refer to Battery System Specifications for the proper specifications. Replace an incorrect battery, as required. 2. The battery terminal connections are loose or corroded. 2. Refer to Battery Cable for the proper cable diagnosis and testing procedures. Clean and tighten the battery terminal connections, as required. 3. The electrical system ignition-off draw is excessive. 3. Refer to the IGNITION-OFF DRAW TEST Standard Procedure for the proper test procedures. Repair the faulty electrical system, as required. 4. The battery is faulty. 4. Test the battery using the Micro 420 battery tester. Refer to Standard Procedures for additional test procedures. Replace the faulty battery, as required. 5. The starting system is faulty. 5. Determine if the starting system is performing to specifications. Refer to Starting System for the proper starting system diagnosis and testing procedures. Repair the faulty starting system, as required. 6. The charging system is faulty. 6. Determine if the charging system is performing to specifications. Refer to Charging System for charging system diagnosis and testing procedures. Repair the faulty charging system, as required. 7. Electrical loads exceed the output of the charging system. 7. Inspect the vehicle for aftermarket electrical equipment which might cause excessive electrical loads. 8. Slow driving or prolonged idling with high-amperage draw loads in use. 8. Advise the vehicle operator, as required. 1. The battery is faulty. 1. Test the battery using the Micro 420 battery tester.. Charge or replace the faulty battery, as required. ABNORMAL BATTERY DISCHARGING Any of the following conditions can result in abnormal battery discharging: 1. A faulty or incorrect charging system component. Refer to Charging System for additional charging system diagnosis and testing procedures. 2. A faulty or incorrect battery. Use Micro 420 tester and refer to Battery System for additional battery diagnosis and testing procedures. 3. A faulty circuit or component causing excessive ignition-off draw. 4. Electrical loads that exceed the output of the charging system. This can be due to equipment installed after manufacture, or repeated short trip use. 5. A faulty or incorrect starting system component. Refer to Starting System for the proper starting system diagnosis and testing procedures. 6. Corroded or loose battery posts and/or terminal clamps. 7. Slow driving speeds (heavy traffic conditions) or prolonged idling, with high-amperage draw loads in use. BATTERY SYSTEM RS 8F - 5 BATTERY SYSTEM (Continued) CLEANING The following information details the recommended cleaning procedures for the battery and related components. In addition to the maintenance schedules found in this service manual and the owner’s manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service. (1) Clean the battery cable terminal clamps of all corrosion. Remove any corrosion using a wire brush or a post and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 1). Fig. 2 Clean Battery - Typical 1 - CLEANING BRUSH 2 - WARM WATER AND BAKING SODA SOLUTION 3 - BATTERY Fig. 1 Clean Battery Cable Terminal Clamp - Typical 1 - TERMINAL BRUSH 2 - BATTERY CABLE (2) Clean the battery tray and battery holddown hardware of all corrosion. Remove any corrosion using a wire brush and a sodium bicarbonate (baking soda) and warm water cleaning solution. Paint any exposed bare metal. (3) If the removed battery is to be reinstalled, clean the outside of the battery case and the top cover with a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film (Fig. 2). Rinse the battery with clean water. Ensure that the cleaning solution does not enter the battery cells through the vent holes. If the battery is being replaced, refer to Battery System Specifications for the factory-installed battery specifications. Confirm that the replacement battery is the correct size and has the correct ratings for the vehicle. (4) Clean the battery thermowrap with a sodium bicarbonate (baking soda) and warm water cleaning solution using a soft bristle parts cleaning brush to remove any acid film. (5) Clean any corrosion from the battery terminal posts with a wire brush or a post and terminal cleaner, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 3). INSPECTION The following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance schedules found in this service manual and the owner’s manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service. (1) Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a damaged or deformed terminal clamp. (2) Inspect the battery tray and battery holddown hardware for damage. Replace any damaged parts. (3) Slide the thermowrap off of the battery case. Inspect the battery case for cracks or other damage that could result in electrolyte leaks. Also, check the battery terminal posts for looseness. Batteries with damaged cases or loose terminal posts must be replaced. 8F - 6 BATTERY SYSTEM RS BATTERY SYSTEM (Continued) SPECIFICATIONS Fig. 3 Clean Battery Terminal Post - Typical 1 - TERMINAL BRUSH 2 - BATTERY CABLE 3 - BATTERY (4) Inspect the battery thermowrap for tears, cracks, deformation or other damage. Replace any battery thermal guard that has been damaged. (5) Inspect the battery built-in test indicator sight glass(if equipped) for an indication of the battery condition. If the battery is discharged, charge as required. Refer to Standard Procedures for the proper battery built-in indicator test procedures. Also refer to Standard Procedures for the proper battery charging procedures. The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment specification for the vehicle being serviced. Battery sizes and ratings are discussed in more detail below. • Group Size - The outside dimensions and terminal placement of the battery conform to standards established by the Battery Council International (BCI). Each battery is assigned a BCI Group Size number to help identify a correctly-sized replacement. • Cold Cranking Amperage - The Cold Cranking Amperage (CCA) rating specifies how much current (in amperes) the battery can deliver for thirty seconds at -18° C (0° F). Terminal voltage must not fall below 7.2 volts during or after the thirty second discharge period. The CCA required is generally higher as engine displacement increases, depending also upon the starter current draw requirements. • Reserve Capacity - The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for battery terminal voltage to fall below 10.5 volts, at a discharge rate of 25 amperes. RC is determined with the battery fully-charged at 26.7° C (80° F). This rating estimates how long the battery might last after a charging system failure, under minimum electrical load. • Ampere-Hours - The Ampere-Hours (AH) rating specifies the current (in amperes) that a battery can deliver steadily for twenty hours, with the voltage in the battery not falling below 10.5 volts. This rating is also sometimes identified as the twentyhour discharge rating. BATTERY CLASSIFICATIONS & RATINGS Part Number BCI Group Size Classification Cold Cranking Amperage Reserve Capacity Ampere Hours Load Test Amperage 4686158AB 34 500 110 Minutes 60 250 4727159AB 34 600 120 Minutes 66 300 4727242AB DIN H6 600 120 Minutes 66 300 5033235AA 34 700 95 Minutes 48 350 BATTERY SYSTEM RS 8F - 7 BATTERY SYSTEM (Continued) SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS Fig. 4 MAINTENANCE-FREE DIESEL ENGINE BATTERY MICRO 420 BATTERY TESTER BATTERY DESCRIPTION There are three different batteries available on this model. Vehicles equipped with a diesel engine utilize a spiral wound plate designed battery with recombination technology. This is a maintenance-free battery that is capable of delivering more power than a conventional battery. This additional power is required by a diesel engine during cold cranking. Vehicles equipped with a gasoline engine utilize a conventional battery. Refer to the following information for detailed differences and descriptions of these batteries. SPIRAL PLATE BATTERY - DIESEL ENGINE Spiral plate technology takes the elements of traditional batteries - lead and sulfuric acid - to the next level. By tightly winding layers of spiral grids and acid-permeated vitreous separators into cells, the manufacturer has developed a battery with more power and service life than conventional batteries the same size. The spiral plate battery is completely, permanently sealed. Through gas recombination, hydrogen and oxygen within the battery are captured during normal charging and reunited to form the water within the electrolyte, eliminating the need to add distilled water. Therefore, these batteries have non-removable battery vent caps (Fig. 4). Water cannot be added to this battery. The acid inside an spiral plate battery is bound within the vitreous separators, ending the threat of acid leaks. This feature allows the battery to be installed in any position anywhere in the vehicle. Spiral plate technology is the process by which the plates holding the active material in the battery are wound tightly in coils instead of hanging flat, like conventional batteries. This design has a lower internal resistance and also increases the active material surface area. WARNING: NEVER EXCEED 14.4 VOLTS WHEN CHARGING A SPIRAL PLATE BATTERY. PERSONAL INJURY AND/OR BATTERY DAMAGE MAY RESULT. Due to the maintanance-free design, distilled water cannot be added to this battery. Therefore, if more than 14.4 volts are used during the spiral plate battery charging process, water vapor can be exhausted through the pressure-sensitive battery vents and lost for good. This can permanently damage the spiral plate battery. Never exceed 14.4 volts when charging a spiral plate battery. Personal injury and/or battery damage may result. 8F - 8 BATTERY SYSTEM RS BATTERY (Continued) CONVENTIONAL BATTERY - GASOLINE ENGINE Fig. 6 Maintenance-Free Battery Fig. 5 BATTERY CELL CAP REMOVAL/ INSTALLATION - LOW-MAINTANANCE GASOLINE ENGINE BATTERY 1 - BATTERY CELL CAP 2 - BATTERY CASE Low-maintenance batteries are used on vehicles equipped with a gasoline engine, these batteries have removable battery cell caps (Fig. 5). Water can be added to this battery. Under normal service, the composition of this battery reduces gassing and water loss at normal charge rates. However these batteries may require additional distilled water after years of service. Maintenance-free batteries are standard factory-installed equipment on this model. Male post type terminals made of a soft lead material protrude from the top of the molded plastic battery case (Fig. 6)to provide the means for connecting the battery to the vehicle electrical system. The battery positive terminal post is visibly larger in diameter than the negative terminal post, for easy identification. The letters POS and NEG are also molded into the top of the battery case adjacent to their respective positive and negative terminal posts for additional identification confirmation. This battery is designed to provide a safe, efficient and reliable means of storing electrical energy in a chemical form. This means of energy storage allows the battery to produce the electrical energy required to operate the engine starting system, as well as to operate many of the other vehicle accessory systems 1 - POSITIVE POST 2 - VENT 3 - CELL CAP 4 - VENT 5 - CELL CAP 6 - VENT 7 - NEGATIVE POST 8 - INDICATOR EYE (if equipped) 9 - ELECTROLYTE LEVEL 10 - PLATE GROUPS 11 - MAINTENANCE-FREE BATTERY for limited durations while the engine and/or the charging system are not operating. The battery is made up of six individual cells that are connected in series. Each cell contains positively charged plate groups that are connected with lead straps to the positive terminal post, and negatively charged plate groups that are connected with lead straps to the negative terminal post. Each plate consists of a stiff mesh framework or grid coated with lead dioxide (positive plate) or sponge lead (negative plate). Insulators or plate separators made of a non-conductive material are inserted between the positive and negative plates to prevent them from contacting or shorting against one another. These dissimilar metal plates are submerged in a sulfuric acid and water solution called an electrolyte. Some factory-installed batteries have a built-in test indicator (hydrometer). The color visible in the sight glass of the indicator will reveal the battery condition. For more information on the use of the built-in test indicator, refer to Standard Procedures The chemical composition of the metal coated plates within the low-maintenance battery reduces battery gassing and water loss, at normal charge and discharge rates. Therefore, the battery should not require additional water in normal service. If the electrolyte level in this battery does become low, distilled water must be added. However, rapid loss of RS BATTERY SYSTEM 8F - 9 BATTERY (Continued) electrolyte can be caused by an overcharging condition. Be certain to diagnose the charging system after replenishing the water in the battery for a low electrolyte condition and before returning the vehicle to service. Refer to Charging System for additional information. The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment specification for the vehicle being serviced. Refer to Battery Specifications in this group for the location of the proper factory-installed battery specifications. OPERATION The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electrical current from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. The sulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly change to lead sulfate. At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, causing the electrolyte to become mainly water. The chemical changes within the battery are caused by the movement of excess or free electrons between the positive and negative plate groups. This movement of electrons produces a flow of electrical current through the load device attached to the battery terminals. As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage potential of each cell is reduced. However, by charging the battery with a voltage higher than that of the battery itself, the battery discharging process is reversed. Charging the battery gradually changes the sulfated lead plates back into sponge lead and lead dioxide, and the water back into sulfuric acid. This action restores the difference in the electron charges deposited on the plates, and the voltage potential of the battery cells. For a battery to remain useful, it must be able to produce high-amperage current over an extended period. A battery must also be able to accept a charge, so that its voltage potential may be restored. The battery is vented to release excess hydrogen gas that is created when the battery is being charged or discharged. However, even with these vents, hydrogen gas can collect in or around the battery. If hydrogen gas is exposed to flame or sparks, it may ignite. If the electrolyte level is low, the battery may arc internally and explode. If the battery is equipped with removable cell caps, add distilled water whenever the electrolyte level is below the top of the plates. If the battery cell caps cannot be removed, the battery must be replaced if the electrolyte level becomes low. DIAGNOSIS AND TESTING - BATTERY The battery must be completely charged and the terminals should be properly cleaned and inspected before diagnostic procedures are performed. Refer to Battery System Cleaning for the proper cleaning procedures, and Battery System Inspection for the proper battery inspection procedures. Refer to Standard Procedures for the proper battery charging procedures. MICRO 420 ELECTRICAL SYSTEM TESTER The Micro420 automotive battery tester is designed to help the dealership technicians diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction manual is not available refer to the standard procedure in this section, which includes the directions for using the Micro420 electrical system tester. WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING OR LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN. A battery that will not accept a charge is faulty, and must be replaced. Further testing is not required. A fully-charged battery must be load tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the load test, is faulty and must be replaced. 8F - 10 BATTERY SYSTEM RS BATTERY (Continued) NOTE: Completely discharged batteries may take several hours to accept a charge. Refer to Standard Procedures for the proper battery charging procedures. STANDARD PROCEDURE STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING Vehicles equipped with a diesel engine utilize a unique spiral plate battery. This battery has a maximum charging voltage that must be used in order to restore the battery to its full potential, failure to use the following spiral plate battery charging procedure could result in damage to the battery or personal injury. Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when: • Micro 420 electrical system tester indicates battery is OK. • Open-circuit voltage of the battery is 12.65 volts or above. • Battery passes Load Test multiple times. WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSISTBOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Do not exceed 14.4 volts while charging a battery. CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continuing the charging operation. Damage to the battery may result. After the battery has been charged to 12.6 volts or greater, perform a load test to determine the battery cranking capacity. Refer to Standard Procedures for the proper battery load test procedures. If the battery will endure a load test, return the battery to service. If the battery will not endure a load test, it is faulty and must be replaced. Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. Refer to Battery System Cleaning for the proper battery system cleaning procedures, and Bat- tery System Inspection for the proper battery system inspection procedures. CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced. (1) Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Fig. 7). If the reading is below ten volts, the battery charging current will be low. It could take some time before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers. Fig. 7 Voltmeter - Typical (2) Disconnect and isolate the battery negative cable. Connect the battery charger leads. Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry. (3) Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner. BATTERY SYSTEM RS 8F - 11 BATTERY (Continued) CHARGE RATE TABLE Voltage Hours 14.4 volts maximum up to 4 hours 13.0 to 14 volts up to 8 hours 12.9 volts or less up to 16 hours CHARGING TIME REQUIRED The time required to charge a battery will vary, depending upon the following factors: • Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery. • Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage). • Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies eight amperes will require a shorter charging time. • State-Of-Charge - A completely discharged battery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the battery charges, the specific gravity of the electrolyte will gradually rise. The Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-ofcharge and the charger capacity. BATTERY CHARGING TIME TABLE Charging Amperage Open Circuit Voltage 5 Amps 8 Amps Hours Charging @ 21° C (70° F) 12.25 to 12.49 6 hours 3 hours 12.00 to 12.24 10 hours 5 hours 10.00 to 11.99 14 hours 7 hours Below 10.00 18 hours 9 hours STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING Vehicles equipped with a diesel engine utilize a unique spiral plate battery. This battery has a maximum charging voltage that must be used in order to restore the battery to its full potential, failure to use the spiral plate battery charging procedure could result in damage to the battery or personal injury. Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when: • Micro 420 electrical system tester indicates battery is OK. • Three hydrometer tests, taken at one-hour intervals, indicate no increase in the temperature-corrected specific gravity of the battery electrolyte. • Open-circuit voltage of the battery is 12.64 volts or above. WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN. WARNING: IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS, BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS. CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Do not exceed sixteen volts while charging a battery. Damage to the vehicle electrical system components may result. CAUTION: Battery electrolyte will bubble inside the battery case during normal battery charging. Electrolyte boiling or being discharged from the battery vents indicates a battery overcharging condition. Immediately reduce the charging rate or turn off the charger to evaluate the battery condition. Damage to the battery may result from overcharging. 8F - 12 BATTERY SYSTEM RS BATTERY (Continued) CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continuing the charging operation. Damage to the battery may result. After the battery has been charged to 12.4 volts or greater, retest the battery with the micro 420 tester or perform a load test to determine the battery cranking capacity. Refer to Standard Procedures for the proper battery load test procedures. If the battery will endure a load test, return the battery to service. If the battery will not endure a load test, it is faulty and must be replaced. Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. Refer to Battery System Cleaning for the proper battery system cleaning procedures, and Battery System Inspection for the proper battery system inspection procedures. CHARGING A COMPLETELY DISCHARGED BATTERY The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced. (1) Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Fig. 8). If the reading is below ten volts, the battery charging current will be low. It could take some time before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers. Fig. 8 Voltmeter - Typical (2) Disconnect and isolate the battery negative cable. Connect the battery charger leads. Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry. (3) Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner. CHARGE RATE TABLE Voltage Hours 16.0 volts maximum up to 10 min. 14.0 to 15.9 volts up to 20 min. 13.9 volts or less up to 30 min. CHARGING TIME REQUIRED The time required to charge a battery will vary, depending upon the following factors: • Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery. • Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage). • Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies twenty amperes or more will require a shorter charging time. • State-Of-Charge - A completely discharged battery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the battery charges, the specific gravity of the electrolyte will gradually rise. The Conventional Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity. BATTERY SYSTEM RS 8F - 13 BATTERY (Continued) CONVENTIONAL BATTERY CHARGING TIME TABLE Charging Amperage Open Circuit Voltage 5 Amps 10 Amps 20 Amps Hours Charging @ 21° C (70° F) greater, it may be load tested to reveal its cranking capacity. Refer to Standard Procedures for the proper battery load test procedures. OPEN CIRCUIT VOLTAGE TABLE Open Circuit Voltage Charge Percentage 11.7 volts or less 0% 12.25 to 12.49 6 hours 3 hours 1.5 hours 12.00 to 12.24 10 hours 5 hours 2.5 hours 12.0 volts 25% 12.2 volts 50% 12.45 volts 75% 12.65 volts or more 100% 10.00 to 11.99 14 hours 7 hours 3.5 hours Below 10.00 18 hours 9 hours 4.5 hours STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery. This test can be used if no other battery tester is available. Before proceeding with this test, completely charge the battery. Refer to Standard Procedures for the proper battery charging procedures. (1) Before measuring the open-circuit voltage, the surface charge must be removed from the battery. Turn on the headlamps for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize. (2) Disconnect and isolate both battery cables, negative cable first. (3) Using a voltmeter connected to the battery posts (see the instructions provided by the manufacturer of the voltmeter), measure the open-circuit voltage (Fig. 9). Fig. 9 Testing Open-Circuit Voltage - Typical See the Open-Circuit Voltage Table. This voltage reading will indicate the battery state-of-charge, but will not reveal its cranking capacity. If a battery has an open-circuit voltage reading of 12.4 volts or STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.015 to 0.025 ampere) with the ignition switch in the Off position, and all non-ignition controlled circuits in proper working order. Up to twenty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty-one days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty-one days or more (stored), remove the IOD fuse from the Integrated Power Module (IPM). This will reduce battery discharging. Excessive IOD can be caused by: • Electrical items left on. • Faulty or improperly adjusted switches. • Faulty or shorted electronic modules and components. • An internally shorted generator. • Intermittent shorts in the wiring. If the IOD is over twenty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. (1) Verify that all electrical accessories are off. Turn off all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. (2) Disconnect the battery negative cable. (3) Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter 8F - 14 BATTERY SYSTEM RS BATTERY (Continued) between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multimeter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. (4) After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Integrated Power Module (IPM), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information in this service manual for complete Integrated Power Module fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. (5) Allow twenty minutes for the IOD to stabilize and observe the multi-meter reading. The low-amperage IOD should not exceed twenty-five milliamperes (0.025 ampere). If the current draw exceeds twentyfive milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 4. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL The following procedure can be used to check the electrolyte level in a low-maintenance lead-acid battery. (1) Unscrew and remove the battery cell caps with a flat-bladed screw driver (Fig. 10). Fig. 10 BATTERY CELL CAP REMOVAL/ INSTALLATION - LOW-MAINTENANCE BATTERY ONLY 1 - BATTERY CELL CAP 2 - BATTERY CASE WARNING: NEVER PUT YOUR FACE NEAR A GASSING, HOT OR SWELLED BATTERY. SERIOUS PERSONAL INJURY MAY RESULT. (2) Wearing safety glasses, look through the battery cell cap holes to determine the level of the electrolyte in the battery. The electrolyte should be above the hooks inside the battery cells (Fig. 11). (3) Add only distilled water until the electrolyte is above the hooks inside the battery cells (Fig. 11). REMOVAL - BATTERY WARNING: A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES AND SAFETY GLASSES SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. BATTERY SYSTEM RS 8F - 15 BATTERY (Continued) Fig. 11 HOOK INSIDE BATTERY CELLS - LOWMAINTENANCE BATTERY ONLY 1 - TOP OF BATTERY 2 - HOOK INSIDE BATTERY CELLS WARNING: REMOVE METALLIC JEWELRY TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. Fig. 12 BATTERY POSITION & ORIENTATION 1 - BATTERY THERMOWRAP (IF EQUIPPED) 2 - INTEGRATED POWER MODULE 3 - FRONT CONTROL MODULE (1) Verify that the ignition switch and all accessories are OFF. (2) Disconnect the battery cables from the battery posts, negative first (Fig. 12). (3) Remove the battery hold down retaining nut. (4) Remove the battery hold down bracket. (5) Remove the battery from the vehicle. When installing a battery into the battery tray, be certain that the hold down hardware is properly installed and that the fasteners are tightened to the proper specifications. Improper hold down fastener tightness, whether too loose or too tight, can result in damage to the battery, the vehicle or both. Refer to Battery Hold Downs in this section of this service manual for the location of the proper battery hold down installation procedures, including the proper hold down fastener tightness specifications. INSTALLATION OPERATION (1) Position the battery in the battery tray. (2) Install the battery hold down bracket and retaining nut. Torque the nut to 20 N·m (180 in. lbs.). (3) Connect the battery cables to the battery posts, positive cable first. Torque terminal fasteners to 8.5 N·m (75 in. lbs.). The battery holddown secures the battery in the battery tray. This holddown is designed to prevent battery movement during the most extreme vehicle operation conditions. Periodic removal and lubrication of the battery holddown hardware is recommended to prevent hardware seizure at a later date. BATTERY HOLDDOWN NOTE: Never operate a vehicle without a battery holddown device properly installed. Damage to the vehicle, components and battery could result. DESCRIPTION The battery hold down hardware consists of a molded plastic lip that is integral to the outboard edge of the battery tray and support unit, a molded steel hold down bracket and a single hex nut with a coned washer. REMOVAL All of the battery hold down hardware can be serviced without removal of the battery or the battery tray and support unit. 8F - 16 BATTERY SYSTEM RS BATTERY HOLDDOWN (Continued) (1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. (2) Remove the nut with washer that secures the battery hold down bracket to the battery tray and support unit. (3) Remove the battery hold down bracket from the battery tray and support unit. INSTALLATION (1) Install the battery hold down bracket in the battery tray and support unit. (2) Install the nut with washer that secures the battery hold down bracket to the battery tray and support unit. Torque to 20 N·m (180 in. lbs.). BATTERY CABLES 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. Refer to Wiring Diagrams in the index of this service manual for the location of the proper battery cable wire gauge information. A clamping type female battery terminal made of stamped metal is attached to one end of the battery cable wire. A square headed pinch-bolt and hex 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 solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. The battery cables cannot be repaired and, if damaged or faulty they must be replaced. 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 models. Refer to Wiring Diagrams in the index of this service manual for the location of more information on the various wiring circuits included in the battery wire harness for the vehicle being serviced. 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. The battery positive cable terminal clamp is attached to the ends of two wires. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Integrated Power Module (IPM), 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 is also attached to the ends of two wires. One wire has an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a stud on the left side of the engine cylinder block. The other wire has an eyelet terminal that connects the battery negative cable to the vehicle body through a ground screw on the left front fender inner shield, near the battery. DIAGNOSIS AND TESTING - BATTERY CABLE 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. BATTERY SYSTEM RS 8F - 17 BATTERY CABLES (Continued) 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 is located in the Intelligent Power Module (IPM), in the engine compartment. See the fuse and relay layout label affixed to the underside of the IPM cover for ASD relay identification and location. (1) Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp (Fig. 13). 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. 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. Fig. 14 TEST BATTERY POSITIVE CONNECTION RESISTANCE - TYPICAL 1 - VOLTMETER 2 - BATTERY (3) Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud (Fig. 15). 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. Fig. 13 TEST BATTERY NEGATIVE CONNECTION RESISTANCE - TYPICAL 1 - VOLTMETER 2 - BATTERY (2) Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp (Fig. 14). Rotate and hold the ignition Fig. 15 TEST BATTERY POSITIVE CABLE RESISTANCE - TYPICAL 1 - BATTERY 2 - VOLTMETER 3 - STARTER MOTOR 8F - 18 BATTERY SYSTEM RS BATTERY CABLES (Continued) (4) Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block (Fig. 16). 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. (2) One at a time, trace and install the battery cable retaining fasteners and routing clips until the desired cable is properly installed in the engine wire harness assembly. (3) Install the tape on the engine wire harness assembly. (4) Install the battery thermowrap (if equipped) on the battery tray. (5) Connect the negative battery cable terminal. BATTERY TRAY DESCRIPTION Fig. 16 TEST GROUND CIRCUIT RESISTANCE TYPICAL 1 - VOLTMETER 2 - BATTERY 3 - ENGINE GROUND REMOVAL The battery cables on this model may include portions of wiring circuits for the generator and other components on the vehicle. If battery cable replacement is required, it will be necessary to extract the cables out of the engine wire harness assembly. Use care not to damage the other wires and circuits which are also packaged into the engine wire harness assembly. (1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. (2) Disconnect and isolate the negative battery cable terminal. (3) Remove the battery thermowrap (if equipped) from the battery tray. (4) Remove the tape from the engine wire harness assembly, to access the desired battery cable. (5) One at a time, trace and disconnect the battery cable retaining fasteners and routing clips until the desired cable is free from the vehicle. (6) Feed the battery cable out of the vehicle. INSTALLATION (1) Position the battery cable in the vehicle. Fig. 17 RS BATTERY TRAY 1 - ENGINE VACUUM RESERVOIR 2 - BATTERY TRAY ASSEMBLY 3 - DRAINAGE HOSE The battery is mounted in a molded plastic battery tray and support unit located in the left front corner of the engine compartment. The battery tray and support unit is secured with two nuts, one is located directly under the battery and the other is located on the right side of the tray which also serves as a coolant bottle neck retaining bolt. An additional bolt is located directly under the battery. The battery tray and support unit also includes a engine vacuum reservoir, located in the rear of the unit (Fig. 17). And a drainage hose, located in the front of the unit (Fig. 17). BATTERY SYSTEM RS 8F - 19 BATTERY TRAY (Continued) OPERATION The battery tray provides a secure mounting location and supports the battery. The battery tray also provides the anchor point for the battery holddown hardware. The battery tray and the battery holddown hardware combine to secure and stabilize the battery in the engine compartment, which prevents battery movement during vehicle operation. Unrestrained battery movement during vehicle operation could result in damage to the vehicle, the battery, or both. The battery tray used on this model also includes a engine vacuum reservoir and drainage hose. The vacuum reservoir provides a storage container for engine vacuum. Refer to the engine section of the service manual for more engine vacuum information. The drainage hose provides means for any liquid that might collect in the bottom of the battery tray to drain under the vehicle. (4) Pull battery tray up far enough to disconnect the engine vacuum harness hose from the battery tray mounted, vacuum reservoir. (5) Remove the battery tray from the vehicle. INSTALLATION (1) Position the battery tray in the vehicle. (2) Connect the engine vacuum harness hose on the battery tray mounted vacuum reservoir. (3) Position drainage hose and install the battery tray retaining fasteners (Fig. 18). (4) Install the battery in the vehicle. Refer to the procedure in this section. (5) Connect the negative battery cable. THERMOWRAP DESCRIPTION REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the battery from the vehicle. Refer to the procedure in this section. (3) Remove the battery tray retaining fasteners (Fig. 18). Fig. 19 BATTERY POSITION & ORIENTATION 1 - BATTERY THERMOWRAP (IF EQUIPPED) 2 - INTEGRATED POWER MODULE 3 - FRONT CONTROL MODULE A one-piece slip-on thermowrap unit shields the battery case from engine compartment heat (Fig. 19). Fig. 18 BATTERY TRAY POSITION & ORIENTATION 1 - BATTERY TRAY RETAINING FASTENERS 8F - 20 BATTERY SYSTEM RS THERMOWRAP (Continued) OPERATION The thermowrap protects the battery from engine compartment temperature extremes. The temperature of the battery can affect battery life. The air trapped in the padded material of the thermowrap creates a dead air space, which helps to insulate the sides of the battery case from the air temperature found in the surrounding engine compartment. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Disconnect the positive battery cable. (3) Lift the battery thermowrap straight up to remove from the battery. INSTALLATION (1) Position the thermowrap on the battery. (2) Connect the negative and positive battery cables. CHARGING RS 8F - 21 CHARGING TABLE OF CONTENTS page CHARGING DESCRIPTION - CHARGING SYSTEM . OPERATION - CHARGING SYSTEM . . . DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . . . SPECIFICATIONS GENERATOR .................. TORQUE . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS ................. BATTERY TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . GENERATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . 21 . . . . . . 22 . . . . . . 23 . . . . . . 23 . . . . . . 23 . . . . . . 24 . . . . . . 24 . . . . . . 24 . . . . . . 24 . . . . . . 24 CHARGING DESCRIPTION - CHARGING SYSTEM The charging system consists of: • Generator • Decoupler Pulley (If equipped) • Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM) • Ignition switch (refer to the Ignition System section for information) • Battery (refer to the Battery section for information) • Inlet Air Temperature (calculated battery temperature) • Voltmeter (refer to the Instrument Cluster section for information if equipped) • Wiring harness and connections (refer to the Wiring section for information) • Accessory drive belt (refer to the Cooling section for more information) OPERATION - CHARGING SYSTEM The charging system is turned on and off with the ignition switch. The system is on when the engine is running and the ASD relay is energized. The ASD relay is energized when the PCM grounds the ASD control circuit. This voltage is connected through the PCM or IPM (intelligent power module) (if equipped) and supplied to one of the generator field terminals (Gen. Source +) at the back of the generator. page REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . . . . REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . INSTALLATION INSTALLATION - 2.4L ............. INSTALLATION - 3.3/3.8L . . . . . . . . . . . GENERATOR DECOUPLER PULLEY DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . VOLTAGE REGULATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . 24 . . . . . 25 . . . . . 25 . . . . . 25 . . . . . 26 . . . . . 26 . . . . . 26 . . . . . 26 . . . . . 27 . . . . . 27 The generator is driven by the engine through a serpentine belt and pulley or decoupler pulley arrangement. The amount of DC current produced by the generator is controlled by the EVR (field control) circuitry contained within the PCM. This circuitry is connected in series with the second rotor field terminal and ground. An Inlet air temperature sensor is used to calculate the temperature near the battery. This temperature data, along with data from monitored line voltage (battery voltage sense circuit), is used by the PCM to vary the battery charging rate. This is done by cycling the ground path to control the strength of the rotor magnetic field. The PCM then compensates and regulates generator current output accordingly to maintain system voltage at the targeted system voltage based on battery temperature. All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including EVR (field control) circuitry, are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects and illuminate the (MIL) lamp. Refer to On-Board Diagnostics in the Electronic Control Modules(Refer to 8 ELECTRICAL/ELECTRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE DESCRIPTION) section for more DTC information. 8F - 22 CHARGING RS CHARGING (Continued) The Check Gauges Lamp (if equipped) or Battery Lamp monitors: charging system voltage, engine coolant temperature and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. The signal to activate the lamp is sent via the PCI bus circuits. The lamp is located on the instrument panel. Refer to the Instrument Cluster section for additional information. The PCM uses the inlet air temperature sensor to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as the calculated battery temperature increases. The ambient temperature sensor is used to control the battery voltage based upon ambient temperature (approximation of battery temperature). The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the OBD system. Some circuits are checked continuously and some are checked only under certain conditions. If the OBD system senses that a monitored circuit is bad, it will put a DTC into electronic memory. The DTC will stay in electronic memory as long as the circuit continues to be bad. The PCM is programmed to clear the memory after 50 engine starts if the problem does not occur again. DIAGNOSTIC TROUBLE CODES A DTC description can be read using the DRBIIIt scan tool. Refer to the appropriate Powertrain Diagnostic Procedures manual for information. A DTC does not identify which component in a circuit is bad. Thus, a DTC should be treated as a symptom, not as the cause for the problem. In some cases, because of the design of the diagnostic test procedure, a DTC can be the reason for another DTC to be set. Therefore, it is important that the test procedures be followed in sequence, to understand what caused a DTC to be set. ERASING DIAGNOSTIC TROUBLE CODES The DRBIIIt Scan Tool must be used to erase a DTC. The following procedures may be used to diagnose the charging system if: • the check gauges lamp or battery lamp is illuminated with the engine running • the voltmeter (if equipped) does not register properly • an undercharged or overcharged battery condition occurs. Remember that an undercharged battery is often caused by: • accessories being left on with the engine not running • a faulty or improperly adjusted switch that allows a lamp to stay on. Refer to Ignition-Off Draw Test (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ BATTERY - STANDARD PROCEDURE) INSPECTION The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the On-Board Diagnostic (OBD) system. Some charging system circuits are checked continuously, and some are checked only under certain conditions. Refer to Diagnostic Trouble Codes in; Powertrain Control Module; Electronic Control Modules for more DTC information. This will include a complete list of DTC’s including DTC’s for the charging system. To perform a complete test of the charging system, refer to the appropriate Powertrain Diagnostic Procedures service manual and the DRBIIIt scan tool. Perform the following inspections before attaching the scan tool. (1) Inspect the battery condition. Refer to the Battery section (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) for procedures. (2) Inspect condition of battery cable terminals, battery posts, connections at engine block, starter solenoid and relay. They should be clean and tight. Repair as required. (3) Inspect all fuses in both the fuseblock and Power Distribution Center (PDC) for tightness in receptacles. They should be properly installed and tight. Repair or replace as required. (4) Inspect generator mounting bolts for tightness. Replace or tighten bolts if required. Refer to the Generator Removal/Installation section of this group for torque specifications (Refer to 8 - ELECTRICAL/ CHARGING - SPECIFICATIONS). (5) Inspect generator drive belt condition and tension. Tighten or replace belt as required. Refer to Belt Tension Specifications(Refer to 7 - COOLING/ ACCESSORY DRIVE - SPECIFICATIONS). CHARGING RS 8F - 23 CHARGING (Continued) (6) Inspect decoupler pulley (if equipped). Ensure decoupler pulley is driving the alternator rotor. (7) Inspect automatic belt tensioner (if equipped). Refer to the Cooling System for more information. (8) Inspect generator electrical connections at generator field, battery output, and ground terminal (if equipped). Also check generator ground wire connection at engine (if equipped). They should all be clean and tight. Repair as required. SPECIFICATIONS GENERATOR Type Engine Minimun Test Amperage Denso 2.4 L 125 Amp Denso 3.3/3.8L 135 Amp or 145 Amp Test Specification: 1. Engine RPM : 2500 RPM ±20 RPM 2. Voltage Output : 14.0 V ± 0.5 V 3. Field Current : 5 amps ± 0.1 amps Part number is located on the side of the generator. TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Battery Hold Down Clamp Bolt 20 14.7 180 Generator B+ Nut 12.4 9.2 110 Battery Terminal Nut 4 Generator Mounting Bolt 2.4L 28.2 20.8 Generator Mounting Bolts 3.3/3.8L 54.2 40 Starter Solenoid Battery Nut 3.3/3.8L 11.3 8.3 Generator Decoupler 109.8 81 SPECIAL TOOLS Fig. 1 GENERATOR DECOUPLER 8433 35 250 100 8F - 24 CHARGING BATTERY TEMPERATURE SENSOR DESCRIPTION The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. OPERATION The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The ambient temperature sensor is used to control the battery voltage based upon ambient temperature (approximation of battery temperature). The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. GENERATOR DESCRIPTION The generator is belt-driven by the engine. It is serviced only as a complete assembly. The generator produces DC voltage at the B+ terminal. If the generator is failed, the generator assembly subcomponents (generator and decoupler pulley) must be inspected for individual failure and replaced accordingly. 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. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. 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 RS current is delivered to the vehicles electrical system through the generator, battery, and ground terminals. Excessive or abnormal noise emitting from the generator may be caused by: • Worn, loose or defective bearings • Loose or defective drive pulley (2.4L) or decoupler (3.3/3.8L) • Incorrect, worn, damaged or misadjusted drive belt • Loose mounting bolts • Misaligned drive pulley • Defective stator or diode • Damaged internal fins REMOVAL REMOVAL - 2.4L (1) Release hood latch and open hood. (2) Disconnect battery negative cable. (3) Disconnect the Inlet Air Temperature sensor. (4) Remove the Air Box, refer to the Engine/Air Cleaner for more information. (5) Remove the EVAP Purge solenoid from its bracket and reposition. (6) Disconnect the push-in field wire connector from back of generator. (7) Remove nut holding B+ wire terminal to back of generator. (8) Separate B+ terminal from generator. (9) Remove accessory drive belt, refer to the Cooling System section for proper procedures. (10) Remove the generator. REMOVAL - 3.3/3.8L (1) Release hood latch and open hood. (2) Disconnect battery negative cable. (3) Disconnect the push-in field wire connector from back of generator. (4) Remove nut holding B+ wire terminal to back of generator. (5) Separate B+ terminal from generator. (6) Raise vehicle and support. (7) Remove the right front lower splash shield. (8) Remove accessory drive belt, refer to the Cooling System section for proper procedures. (9) Remove the lower oil dip stick tube bolt (Fig. 2). (10) Remove wiring harness from the oil dip stick tube (11) Remove the 3 mounting bolts. (12) Lower vehicle. (13) Remove oil dip stick tube from vehicle. (14) Roll and remove the generator from vehicle (Fig. 3). CHARGING RS 8F - 25 GENERATOR (Continued) INSTALLATION INSTALLATION - 2.4L (1) Install the generator. (2) Install the accessory drive belt, refer to the Cooling System section for proper procedures. (3) Connect B+ terminal to generator. (4) Install nut holding B+ wire terminal to back of generator. (5) Connect the push-in field wire connector to back of generator. (6) Install the EVAP Purge solenoid to its bracket. (7) Install the Air Box, refer to the Engine/Air Cleaner for more information. (8) Connect the Inlet Air Temperature sensor. (9) Connect battery negative cable. INSTALLATION - 3.3/3.8L Fig. 2 DIP STICK LOWER BOLT (1) Roll and place generator in position on vehicle (Fig. 3). (2) Install upper bolts to hold generator in place. (3) Lubricate the o-ring. Install oil dip stick tube. (4) Install the upper oil dip stick tube bolt. (5) Place B+ terminal in position on generator. (6) Install nut to hold B+ wire terminal to back of generator. (7) Connect the push-in field wire connector into back of generator. (8) Raise vehicle and support. (9) Install the lower mounting bolt and tighten. (10) Install the lower oil dip stick tube bolt and tighten (Fig. 2). (11) Install accessory drive belt, refer to the Cooling System section for proper procedures. (12) Install the right front lower splash shield. (13) Lower vehicle. (14) Install wiring harness to the oil dip stick tube (15) Connect battery negative cable. (16) Verify generator output rate. GENERATOR DECOUPLER PULLEY Fig. 3 GENERATOR 3.3/3.8L DESCRIPTION The Generator Decoupler is a one way clutch (Fig. 4). It is attached to the generator and replaces the standard pulley. It is a non-serviceable item and is to be replaced as an assembly. It is a dry operation (no grease or lubricants). The operation of it is not temperature sensitive and has a low sensitivity to electrical load. 8F - 26 CHARGING RS GENERATOR DECOUPLER PULLEY (Continued) OPERATION The generator decoupler is a one way clutch and should be replaced as an assembly. It is designed to help reduce belt tension fluctuation, reduce fatigue loads, improve belt life, reduce hubloads on components, and reduce noise. Fig. 4 GENERATOR DECOUPLER 3.3/3.8L DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY CONDITION Does not drive generator (Generator not Charging) POSSIBLE CAUSES Clutch failure CORRECTION Replace Decoupler REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable. (3) Raise vehicle and support. (4) Remove the right front lower splash shield. (5) Remove accessory drive belt, refer to the Cooling System section for proper procedures (Fig. 5). (6) Lower vehicle. (7) Remove the Air Box, refer to the Engine section for more information. (8) Use Special Tool #8433 (Fig. 7) to loosen the Generator Decoupler (Fig. 6). (9) Remove the tool. (10) Remove the Generator Decoupler. INSTALLATION (1) Install the Generator Decoupler to the generator shaft. (2) Use Special Tool #8433 (Fig. 7) to tighten the Generator Decoupler (Fig. 8). Refer to the torque chart for the proper torque. Fig. 5 DRIVE BELT 3.3/3.8L CHARGING RS 8F - 27 GENERATOR DECOUPLER PULLEY (Continued) Fig. 6 DECOUPLER REMOVAL (LITENS) Fig. 8 DECOUPLER INSTALLATION (Litens) VOLTAGE REGULATOR DESCRIPTION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. OPERATION Fig. 7 SPECIAL TOOL 8433 AND DECOUPLER (3) Install the Air Box, refer to the Engine section for more information. (4) Raise vehicle and support. (5) Install accessory drive belt, refer to the Cooling System section for proper procedures (Fig. 5). (6) Install the right front lower splash shield. (7) Lower vehicle. (8) Connect battery negative cable. The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and calculated battery temperature or inlet air temperature sensor (refer to Inlet Air Temperature Sensor, if equipped, for more information ). It then determines a target charging voltage. If sensed battery voltage is lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is at the target voltage. A circuit in the PCM cycles the ground side of the generator field at 250 times per second (250Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information. 8F - 28 STARTING RS STARTING TABLE OF CONTENTS page STARTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - STARTING SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . 28 . . 28 . . 31 . . 33 page SPECIFICATIONS STARTER . . . . . . . . . . Torques . . . . . . . . . . . . STARTER MOTOR REMOVAL REMOVAL - 2.4L . . . . . REMOVAL - 3.3/3.8L . . INSTALLATION INSTALLATION - 2.4L . INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . . 36 . . 33 STARTING DESCRIPTION The starting system has (Fig. 1): • Ignition switch • Starter relay • Transmission Range Sensor or Park/Neutral Switch • Wiring harness • Battery • Starter motor with an integral solenoid • Powertrain Control Module (PCM) OPERATION These components form two separate circuits. A high amperage circuit that feeds the starter motor up to 300+ amps, and a control circuit that operates on less than 20 amps. The PCM controls a double start over-ride safety that does not allow the starter to be engaged if the engine is already running. DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - STARTING SYSTEM TEST For circuit descriptions and diagrams, refer to the Wiring Diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO THE PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING 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. INSPECTION Before removing any unit from the starting system for repair or diagnosis, perform the following inspections: • Battery - Visually inspect the battery for indications of physical damage and loose or corroded cable connections. Determine the state-of-charge and cranking capacity of the battery. Charge or replace the battery, if required. Refer to the Battery section for more information. • Ignition Switch - Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness connections. • Transmission Range Sensor - Visually inspect the transmission range sensor for indications of physical damage and loose or corroded wire harness connections. • Starter Relay - Visually inspect the starter relay for indications of physical damage and loose or corroded wire harness connections. STARTING RS 8F - 29 STARTING (Continued) • Starter - Visually inspect the starter for indications of physical damage and loose or corroded wire harness connections. • Starter Solenoid - Visually inspect the starter solenoid for indications of physical damage and loose or corroded wire harness connections. • Wiring - Visually inspect the wire harness for damage. Repair or replace any faulty wiring, as required. Check for loose or corroded wire harness connections at main engine ground and remote jump post. • Power Distribution Center (PDC) - Visually inspect the B+ connections at the PDC for physical damage and loose or corroded harness connections. Fig. 1 STARTING SYSTEM SCHEMATIC 1 - SOLENOID TERMINAL 2 - STARTER SOLENOID 3 - STARTER MOTOR 4 - STARTER RELAY CONNECTOR 5 - PCM 6 - GROUND CIRCUIT 7 - TRANSMISSION RANGE SENSOR/PARK/NEUTRAL SENSE 8 - IGNITION SWITCH 9 - IGNITION FEED 10 - BATTERY 11 - BATTERY RELAY FEED 12 - POSITIVE CABLE 13 - NEGATIVE CABLE 14 - CLUTCH INTERLOCK SWITCH (MTX ONLY) 8F - 30 STARTING RS STARTING (Continued) STARTING SYSTEM DIAGNOSIS CONDITION STARTER FAILS TO ENGAGE. STARTER ENGAGES, FAILS TO TURN ENGINE. POSSIBLE CAUSE CORRECTION 1. BATTERY DISCHARGED OR FAULTY. 1. REFER TO THE BATTERY SECTION FOR MORE INFORMATION. CHARGE OR REPLACE BATTERY, IF REQUIRED. 2. STARTING CIRCUIT WIRING FAULTY. 2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED CIRCUIT TEST IN THIS SECTION. 3. STARTER RELAY FAULTY. 3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE RELAY, IF NECESSARY. 4. IGNITION SWITCH FAULTY. 4. REFER TO IGNITION SWITCH TEST, IN THE STEERING SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF NECESSARY. 5. PARK/NEUTRAL POSITION SWITCH (AUTO TRANS) FAULTY OR MIS-ADJUSTED. 5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE SWITCH, IF NECESSARY. 6. CLUTCH PEDAL POSITION SWITCH (MAN TRANS) FAULTY. 6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY. 7. STARTER SOLENOID FAULTY. 7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE STARTER ASSEMBLY, IF NECESSARY. 8. STARTER ASSEMBLY FAULTY. 8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY. 9. FAULTY TEETH ON RING GEAR. 9. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED. 10. PCM DOUBLE START OVERRIDE OUTPUT FAILURE. 10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE. 1. BATTERY DISCHARGED OR FAULTY. 1. REFER TO THE BATTERY SECTION FOR MORE INFORMATION. CHARGE OR REPLACE BATTERY AS NECESSARY. 2. STARTING CIRCUIT WIRING FAULTY. 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS NECESSARY. 3. STARTER ASSEMBLY FAULTY. 3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY. 4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND SERVICE PROCEDURES. 5. LOOSE CONNECTION AT BATTERY, PDC, STARTER, OR ENGINE GROUND. 5. INSPECT FOR LOOSE CONNECTIONS. 6. FAULTY TEETH ON RING GEAR. 6. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED. STARTING RS 8F - 31 STARTING (Continued) CONDITION STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS. STARTER DOES NOT DISENGAGE. POSSIBLE CAUSE CORRECTION 1. BROKEN TEETH ON STARTER RING GEAR. 1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE IF NECESSARY. 2. STARTER ASSEMBLY FAULTY. 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY. 1. STARTER IMPROPERLY INSTALLED. 1. INSTALL STARTER. TIGHTEN STARTER MOUNTING HARDWARE TO CORRECT TORQUE SPECIFICATIONS. 2. STARTER RELAY FAULTY. 2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE RELAY, IF NECESSARY. 3. IGNITION SWITCH FAULTY. 3. REFER TO IGNITION SWITCH TEST, IN THE STEERING SECTION. REPLACE SWITCH, IF NECESSARY. 4. STARTER ASSEMBLY FAULTY. 4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY. 5. FAULTY TEETH ON RING GEAR. 5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED. DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST • To disable ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for the proper relay location. (3) Perform a visual inspection of the starter/ starter solenoid for corrosion, loose connections or faulty wiring. (4) Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. (5) Connect a remote starter switch or a jumper wire between the remote battery positive post and terminal 87 of the starter relay connector. (a) If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test. (b) If engine does not crank or solenoid chatters, check wiring and connectors from starter relay to starter solenoid for loose or corroded connections. Particularly at starter terminals. (c) Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter. Inspect the ring gear teeth. STARTER SOLENOID STARTER RELAY WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APPLIED. WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. The starter control circuit has: • Starter motor with integral solenoid • Starter relay • Transmission range sensor, or Park/Neutral Position switch with automatic transmissions • Ignition switch • Battery • All related wiring and connections • Powertrain Control Module (PCM) CAUTION: Before performing any starter tests, the ignition and fuel systems must be disabled. (1) Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests. Refer to Battery Tests. (2) Perform Starter Solenoid test BEFORE performing the starter relay test. RELAY TEST The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. 8F - 32 STARTING RS STARTING (Continued) Remove the starter relay from the PDC as described in this group to perform the following tests: (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. (2) Resistance between terminals 85 and 86 (electromagnet) should be 75 ±5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. (3) Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Starter Relay Pinout Starter Relay Pinout CAV FUNCTION 30 B (+) 85 P/N POSITION SW.SENSE 86 IGNITION SWITCH OUTPUT 87 STARTER RELAY OUTPUT 87A NO CONNECT RELAY CIRCUIT TEST (1) The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. (2) The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. (3) The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. (4) The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position and the clutch pedal is depressed (manual trans). Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position and the clutch pedal is depressed (manual trans), and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure in this group. (5) The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the transmission range sensor only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the transmission range sensor and repair. It is grounded by the PCM if the conditions are right to start the car. For automatic trans. cars the PCM must see Park Neutral switch and near zero engine rpm. For manual trans. cars the PCM only needs to see near zero engine rpm. To diagnose the Park Neutral switch of the trans range sensor refer to the transaxle section for more information. Check for continuity to ground while the ignition switch is in the start position. If not OK and the vehicle has an automatic trans. verify Park Neutral switch opera- RS STARTING 8F - 33 STARTING (Continued) tion. If that checks OK check for continuity between PCM and the terminal 85. Repair open circuit as required. If OK, the PCM may be defective. SAFETY SWITCHES For diagnostics of the Transmission Range Sensor, refer to the Transaxle section for more information. If equipped with Clutch Interlock/Upstop Switch, refer to Diagnosis and Testing in the Clutch section. IGNITION SWITCH After testing starter solenoid and relay, test ignition switch and wiring. Refer to the Ignition Section or Wiring Diagrams for more information. Check all wiring for opens or shorts, and all connectors for being loose or corroded. BATTERY For battery diagnosis and testing, refer to the Battery section for procedures. ALL RELATED WIRING AND CONNECTORS Refer to Wiring Diagrams for more information. (c) Connect negative lead of voltmeter to battery negative terminal, and positive lead to engine block near the battery cable attaching point. Rotate and hold the ignition switch in the START position. If voltage reads above 0.2 volt, correct poor contact at ground cable attaching point. If voltage reading is still above 0.2 volt after correcting poor contacts, replace ground cable. (4) Connect positive voltmeter lead to the starter motor housing and the negative lead to the battery negative terminal. Hold the ignition switch key in the START position. If voltage reads above 0.2 volt, correct poor starter to engine ground. (a) Connect the positive voltmeter lead to the battery positive terminal, and negative lead to battery cable terminal on starter solenoid. Rotate and hold the ignition switch in the START position. If voltage reads above 0.2 volt, correct poor contact at battery cable to solenoid connection. If reading is still above 0.2 volt after correcting poor contacts, replace battery positive cable. (b) If resistance tests do not detect feed circuit failures, replace the starter motor. DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST DIAGNOSIS AND TESTING - FEED CIRCUIT TEST Before proceeding with this operation, review Diagnostic Preparation and Starter Feed Circuit Tests. The following operation will require a voltmeter, accurate to 1/10 of a volt. NOTE: The following results are based upon the vehicle being at room temperature. CAUTION: Ignition and Fuel systems must be disabled to prevent engine start while performing the following tests. (1) To disable the Ignition and Fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for proper relay location. (2) Gain access to battery terminals. (3) With all wiring harnesses and components properly connected, perform the following: (a) Connect the negative lead of the voltmeter to the battery negative post, and positive lead to the battery negative cable clamp. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If voltage is detected, correct poor contact between cable clamp and post. (b) Connect positive lead of the voltmeter to the battery positive post, and negative lead to the battery positive cable clamp. Rotate and hold the ignition switch key in the START position. Observe the voltmeter. If voltage is detected, correct poor contact between the cable clamp and post. The following procedure will require a suitable volt-ampere tester (Fig. 3). Fig. 3 Volt Ampere Tester CAUTION: Before performing any starter tests, the ignition and fuel systems must be disabled. (1) Check battery before performing this test. Battery must be fully charged. (2) Connect a volt-ampere tester to the battery terminals. Refer to the operating instructions provided with the tester being used. 8F - 34 STARTING RS STARTING (Continued) (3) To disable the ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for proper relay location. (4) Verify that all lights and accessories are OFF, and the transmission shift selector is in the PARK and SET parking brake. SPECIFICATIONS CAUTION: Do not overheat the starter motor or draw the battery voltage below 9.6 volts during cranking operations. (5) Rotate and hold the ignition switch in the START position. Observe the volt-ampere tester (Fig. 3). • If voltage reads above 9.6 volts, and amperage draw reads above 280 amps, check for engine seizing or faulty starter. • If voltage reads 12.4 volts or greater and amperage reads 0 to 10 amps, check for corroded cables and/or bad connections. • Voltage below 9.6 volts and amperage draw above 300 amps, the problem is the starter. Replace the starter refer to starter removal. (6) After the starting system problems have been corrected, verify the battery state-of-charge and charge battery if necessary. Disconnect all testing equipment and connect ASD relay. Start the vehicle several times to assure the problem has been corrected. STARTER MANUFACTURER NIPPONDENSO Engine Application 2.4L /3.3/3.8L Power rating 1.2 Kw Voltage 12 VOLTS No. of Fields 4 No. of Poles 4 Brushes 4 Drive Conventional Gear Train Free running Test Voltage 11 Amperage Draw 73 Amp Minimum Speed 3401 RPM SolenoidClosing Voltage 7.5 Volts Cranking Amperage Draw test 150 - 200 Amps. Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase starter amperage draw. Torques DESCRIPTION N·m Ft. Lbs. Starter Mounting Bolts 47.4 35 Starter Solenoid Battery Nut 11.3 8.3 In. Lbs. 100 STARTING RS 8F - 35 STARTER MOTOR REMOVAL REMOVAL - 2.4L (1) Release hood latch and open hood (Fig. 4). Fig. 5 BATTERY CABLE AND FIELD WIRE 2.4L Fig. 4 STARTER 2.4L (2) Disconnect and isolate the battery negative cable. (3) Disconnect solenoid wire connector from terminal (Fig. 5). (4) Remove nut holding B+ wire to terminal. (5) Disconnect solenoid and B+ wires from starter terminals. (6) Remove the lower bolt. (7) Remove the upper bolt and ground wire (Fig. 6). (8) Remove starter. Fig. 6 Upper Bolt and Ground Wire 8F - 36 STARTING RS STARTER MOTOR (Continued) REMOVAL - 3.3/3.8L (7) Remove starter from bellhousing (Fig. 9). (1) Release hood latch and open hood. (2) Disconnect and isolate the battery negative cable. (3) Hoist and support vehicle on safety stands. (4) Remove nut holding B+ terminal to starter solenoid (Fig. 7). Fig. 9 STARTER 3.3/3.8L 1 2 3 4 5 Fig. 7 Starter 1 - SOLENOID CONNECTOR 2 - B+ CONNECTOR (5) Disconnect solenoid connector from starter. (6) Remove bolts holding starter to transaxle bellhousing (Fig. 8). - BELL HOUSING PLATE FLYWHEEL ENGINE MOUNT STARTER SPACER (8) Separate starter spacer from transaxle bellhousing. INSTALLATION INSTALLATION - 2.4L (1) Place starter in position on vehicle. (2) Install the lower bolts to hold starter to transaxle bellhousing. (3) Install the upper bolt and ground wire (Fig. 6). (4) Place solenoid and B+ wires in position on starter terminals (Fig. 5). (5) Install nut to hold B+ wire to terminal. (6) Connect solenoid wire connector onto terminal. (7) Connect battery negative cable. (8) Verify starter operation. INSTALLATION - 3.3/3.8L Fig. 8 Starter Bolts 1 2 3 4 - STARTER STARTER BOLTS TRANSAXLE ENGINE MOUNT (1) Place starter spacer in position on transaxle bellhousing, flange toward flywheel. (2) Place starter in position on bellhousing. (3) Install bolts and ground wire (Fig. 6) to hold starter to transaxle bellhousing. (4) Connect solenoid connector into starter. (5) Install nut to hold B+ terminal to starter solenoid. (6) Lower vehicle. (7) Connect battery negative cable. (8) Verify starter operation. ENGINE SYSTEMS RG 8Fa - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 BATTERY SYSTEM TABLE OF CONTENTS page page BATTERY SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DIAGNOSIS AND TESTING - BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS . . . . . . . 7 BATTERY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING - BATTERY . . . . . . . 9 STANDARD PROCEDURE STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING . . . . . . . . . . . . . . . . . . 10 STANDARD PROCEDURE CONVENTIONAL BATTERY CHARGING. . . . . 11 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 13 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 13 STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL . . . . . . . . . 14 REMOVAL - BATTERY ........... INSTALLATION . . . . . . . . . . . . . . . . . BATTERY HOLDDOWN DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BATTERY CABLES DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BATTERY TRAY DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . THERMOWRAP DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BATTERY SYSTEM the following related components, which are covered in further detail elsewhere in this service manual: • Battery - The storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle. • Battery Cable - The battery cables connect the battery terminal posts to the vehicle electrical system. DESCRIPTION A single 12-volt battery system is standard factoryinstalled equipment on this model. All of the components of the battery system are located within the engine compartment of the vehicle. The service information for the battery system in this vehicle covers . . . . . . . . 15 . . . . . . . . 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . 15 . 16 . 16 ...... ...... CABLE ...... ...... . . 16 . . 16 . 16 . . 18 . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . 19 . 19 . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . 19 . 19 . 19 8Fa - 2 BATTERY SYSTEM RG BATTERY SYSTEM (Continued) • Battery Holddown - The battery holddown hardware secures the battery in the battery tray in the engine compartment. • Battery Thermowrap - The battery thermowarp insulates the battery to protect it from engine compartment temperature extremes. • Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor point for the battery holddown hardware. For battery system maintenance schedules and jump starting procedures, see the owner’s manual in the vehicle glove box. Optionally, refer to Lubrication and Maintenance for the recommended battery maintenance schedules and for the proper battery jump starting procedures. While battery charging can be considered a maintenance procedure, the battery charging procedures and related information are located in the standard procedures section of this service manual. This was done because the battery must be fully-charged before any battery system diagnosis or testing procedures can be performed. Refer to Standard procedures for the proper battery charging procedures. OPERATION The battery system is designed to provide a safe, efficient, reliable and mobile means of delivering and storing electrical energy. This electrical energy is required to operate the engine starting system, as well as to operate many of the other vehicle accessory systems for limited durations while the engine and/or the charging system are not operating. The battery system is also designed to provide a reserve of electrical energy to supplement the charging system for short durations while the engine is running and the electrical current demands of the vehicle exceed the output of the charging system. In addition to delivering, and storing electrical energy for the vehicle, the battery system serves as a capacitor and voltage stabilizer for the vehicle electrical system. It absorbs most abnormal or transient voltages caused by the switching of any of the electrical components or circuits in the vehicle. DIAGNOSIS AND TESTING - BATTERY SYSTEM The battery, starting, and charging systems in the vehicle operate with one another and must be tested as a complete system. In order for the engine to start and the battery to maintain its charge properly, all of the components that are used in these systems must perform within specifications. It is important that the battery, starting, and charging systems be thoroughly tested and inspected any time a battery needs to be charged or replaced. The cause of abnormal battery discharge, overcharging or early battery failure must be diagnosed and corrected before a battery is replaced and before a vehicle is returned to service. The service information for these systems has been separated within this service manual to make it easier to locate the specific information you are seeking. However, when attempting to diagnose any of these systems, it is important that you keep their interdependency in mind. The diagnostic procedures used for the battery, starting, and charging systems include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an induction-type milliampere ammeter, a volt/ohmmeter, a battery charger, a carbon pile rheostat (load tester) and a 12-volt test lamp may be required. All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. Refer to Charging System for the proper charging system onboard diagnostic test procedures. MICRO 420 ELECTRICAL SYSTEM TESTER The Micro 420 automotive battery system tester is designed to help the dealership technicians diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction manual is not available refer to the standard procedure in this section, which includes the directions for using the Micro 420 electrical system tester. BATTERY SYSTEM RG 8Fa - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION THE BATTERY SEEMS WEAK OR DEAD WHEN ATTEMPTING TO START THE ENGINE. POSSIBLE CAUSES CORRECTION 1. The electrical system ignition-off draw is excessive. 1. Refer to the IGNITION-OFF DRAW TEST Standard Procedure for the proper test procedures. Repair the excessive ignition-off draw, as required. 2. The charging system is faulty. 2. Determine if the charging system is performing to specifications. Refer to Charging System for additional charging system diagnosis and testing procedures. Repair the faulty charging system, as required. 3. The battery is discharged. 3. Determine the battery state-of-charge using the Micro 420 battery tester. Refer to the Standard Procedures in this section for additional test procedures. Charge the faulty battery, as required. 4. The battery terminal connections are loose or corroded. 4. Refer to Battery Cables for the proper battery cable diagnosis and testing procedures. Clean and tighten the battery terminal connections, as required. 5. The battery has an incorrect size or rating for this vehicle. 5. Refer to Battery System Specifications for the proper size and rating. Replace an incorrect battery, as required. 6. The battery is faulty. 6. Test the battery using the Micro 420 battery tester. Refer to the Standard Procedures in this section for additional test procedures. Replace the faulty battery, as required. 7. The starting system is faulty. 7. Determine if the starting system is performing to specifications. Refer to Starting System for the proper starting system diagnosis and testing procedures. Repair the faulty starting system, as required. 8. The battery is physically damaged. 8. Inspect the battery for loose terminal posts or a cracked and leaking case. Replace the damaged battery, as required. 8Fa - 4 BATTERY SYSTEM RG BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION THE BATTERY STATE OF CHARGE CANNOT BE MAINTAINED. THE BATTERY WILL NOT ACCEPT A CHARGE. POSSIBLE CAUSES CORRECTION 1. The battery has an incorrect size or rating for this vehicle. 1. Refer to Battery System Specifications for the proper specifications. Replace an incorrect battery, as required. 2. The battery terminal connections are loose or corroded. 2. Refer to Battery Cable for the proper cable diagnosis and testing procedures. Clean and tighten the battery terminal connections, as required. 3. The electrical system ignition-off draw is excessive. 3. Refer to the IGNITION-OFF DRAW TEST Standard Procedure for the proper test procedures. Repair the faulty electrical system, as required. 4. The battery is faulty. 4. Test the battery using the Micro 420 battery tester. Refer to Standard Procedures for additional test procedures. Replace the faulty battery, as required. 5. The starting system is faulty. 5. Determine if the starting system is performing to specifications. Refer to Starting System for the proper starting system diagnosis and testing procedures. Repair the faulty starting system, as required. 6. The charging system is faulty. 6. Determine if the charging system is performing to specifications. Refer to Charging System for charging system diagnosis and testing procedures. Repair the faulty charging system, as required. 7. Electrical loads exceed the output of the charging system. 7. Inspect the vehicle for aftermarket electrical equipment which might cause excessive electrical loads. 8. Slow driving or prolonged idling with high-amperage draw loads in use. 8. Advise the vehicle operator, as required. 1. The battery is faulty. 1. Test the battery using the Micro 420 battery tester.. Charge or replace the faulty battery, as required. BATTERY SYSTEM RG 8Fa - 5 BATTERY SYSTEM (Continued) ABNORMAL BATTERY DISCHARGING Any of the following conditions can result in abnormal battery discharging: 1. A faulty or incorrect charging system component. Refer to Charging System for additional charging system diagnosis and testing procedures. 2. A faulty or incorrect battery. Use Micro 420 tester and refer to Battery System for additional battery diagnosis and testing procedures. 3. A faulty circuit or component causing excessive ignition-off draw. 4. Electrical loads that exceed the output of the charging system. This can be due to equipment installed after manufacture, or repeated short trip use. 5. A faulty or incorrect starting system component. Refer to Starting System for the proper starting system diagnosis and testing procedures. 6. Corroded or loose battery posts and/or terminal clamps. 7. Slow driving speeds (heavy traffic conditions) or prolonged idling, with high-amperage draw loads in use. CLEANING The following information details the recommended cleaning procedures for the battery and related components. In addition to the maintenance schedules found in this service manual and the owner’s manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service. (1) Clean the battery cable terminal clamps of all corrosion. Remove any corrosion using a wire brush or a post and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 1). (2) Clean the battery tray and battery holddown hardware of all corrosion. Remove any corrosion using a wire brush and a sodium bicarbonate (baking soda) and warm water cleaning solution. Paint any exposed bare metal. (3) If the removed battery is to be reinstalled, clean the outside of the battery case and the top cover with a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film (Fig. 2). Rinse the battery with clean water. Ensure that the cleaning solution does not enter the battery cells through the vent holes. If the battery is being replaced, refer to Battery System Specifications for the factory-installed battery specifications. Confirm that the replacement battery is the correct size and has the correct ratings for the vehicle. Fig. 1 Clean Battery Cable Terminal Clamp - Typical 1 - TERMINAL BRUSH 2 - BATTERY CABLE Fig. 2 BATTERY CLEANING- TYPICAL 1 - CLEANING BRUSH 2 - WARM WATER AND BAKING SODA SOLUTION 3 - BATTERY 8Fa - 6 BATTERY SYSTEM RG BATTERY SYSTEM (Continued) (4) Clean the battery thermowrap with a sodium bicarbonate (baking soda) and warm water cleaning solution using a soft bristle parts cleaning brush to remove any acid film. (5) Clean any corrosion from the battery terminal posts with a wire brush or a post and terminal cleaner, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 3). battery terminal posts for looseness. Batteries with damaged cases or loose terminal posts must be replaced. (4) Inspect the battery thermowrap for tears, cracks, deformation or other damage. Replace any battery thermal guard that has been damaged. (5) Inspect the battery built-in test indicator sight glass(if equipped) for an indication of the battery condition. If the battery is discharged, charge as required. Refer to Standard Procedures for the proper battery built-in indicator test procedures. Also refer to Standard Procedures for the proper battery charging procedures. SPECIFICATIONS Fig. 3 Clean Battery Terminal Post - Typical 1 - TERMINAL BRUSH 2 - BATTERY CABLE 3 - BATTERY INSPECTION The following information details the recommended inspection procedures for the battery and related components. In addition to the maintenance schedules found in this service manual and the owner’s manual, it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service. (1) Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a damaged or deformed terminal clamp. (2) Inspect the battery tray and battery holddown hardware for damage. Replace any damaged parts. (3) Slide the thermowrap off of the battery case. Inspect the battery case for cracks or other damage that could result in electrolyte leaks. Also, check the The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment specification for the vehicle being serviced. Battery sizes and ratings are discussed in more detail below. • Group Size - The outside dimensions and terminal placement of the battery conform to standards established by the Battery Council International (BCI). Each battery is assigned a BCI Group Size number to help identify a correctly-sized replacement. • Cold Cranking Amperage - The Cold Cranking Amperage (CCA) rating specifies how much current (in amperes) the battery can deliver for thirty seconds at -18° C (0° F). Terminal voltage must not fall below 7.2 volts during or after the thirty second discharge period. The CCA required is generally higher as engine displacement increases, depending also upon the starter current draw requirements. • Reserve Capacity - The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for battery terminal voltage to fall below 10.5 volts, at a discharge rate of 25 amperes. RC is determined with the battery fully-charged at 26.7° C (80° F). This rating estimates how long the battery might last after a charging system failure, under minimum electrical load. • Ampere-Hours - The Ampere-Hours (AH) rating specifies the current (in amperes) that a battery can deliver steadily for twenty hours, with the voltage in the battery not falling below 10.5 volts. This rating is also sometimes identified as the twentyhour discharge rating. BATTERY SYSTEM RG 8Fa - 7 BATTERY SYSTEM (Continued) BATTERY CLASSIFICATIONS & RATINGS Part Number BCI Group Size Classification Cold Cranking Amperage Reserve Capacity Ampere Hours Load Test Amperage 4686158AB 34 500 110 Minutes 60 250 4727159AB 34 600 120 Minutes 66 300 4727242AB DIN H6 600 120 Minutes 66 300 5033235AA 34 700 95 Minutes 48 350 SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS Fig. 4 MAINTENANCE-FREE DIESEL ENGINE BATTERY MICRO 420 BATTERY TESTER BATTERY DESCRIPTION There are three different batteries available on this model. Vehicles equipped with a diesel engine utilize a spiral wound plate designed battery with recombination technology. This is a maintenance-free battery that is capable of delivering more power than a conventional battery. This additional power is required by a diesel engine during cold cranking. Vehicles equipped with a gasoline engine utilize a conventional battery. Refer to the following information for detailed differences and descriptions of these batteries. SPIRAL PLATE BATTERY - DIESEL ENGINE Spiral plate technology takes the elements of traditional batteries - lead and sulfuric acid - to the next level. By tightly winding layers of spiral grids and acid-permeated vitreous separators into cells, the manufacturer has developed a battery with more power and service life than conventional batteries the same size. The spiral plate battery is completely, permanently sealed. Through gas recombination, hydrogen and oxygen within the battery are captured during normal charging and reunited to form the water within the electrolyte, eliminating the need to add distilled water. Therefore, these batteries have non-removable battery vent caps (Fig. 4). Water cannot be added to this battery. The acid inside an spiral plate battery is bound within the vitreous separators, ending the threat of acid leaks. This feature allows the battery to be installed in any position anywhere in the vehicle. Spiral plate technology is the process by which the plates holding the active material in the battery are wound tightly in coils instead of hanging flat, like conventional batteries. This design has a lower inter- 8Fa - 8 BATTERY SYSTEM RG BATTERY (Continued) nal resistance and also increases the active material surface area. WARNING: NEVER EXCEED 14.4 VOLTS WHEN CHARGING A SPIRAL PLATE BATTERY. PERSONAL INJURY AND/OR BATTERY DAMAGE MAY RESULT. Due to the maintanance-free design, distilled water cannot be added to this battery. Therefore, if more than 14.4 volts are used during the spiral plate battery charging process, water vapor can be exhausted through the pressure-sensitive battery vents and lost for good. This can permanently damage the spiral plate battery. Never exceed 14.4 volts when charging a spiral plate battery. Personal injury and/or battery damage may result. terminals made of a soft lead material protrude from the top of the molded plastic battery case (Fig. 6)to provide the means for connecting the battery to the vehicle electrical system. The battery positive terminal post is visibly larger in diameter than the negative terminal post, for easy identification. The letters POS and NEG are also molded into the top of the battery case adjacent to their respective positive and negative terminal posts for additional identification confirmation. CONVENTIONAL BATTERY - GASOLINE ENGINE Fig. 6 Maintenance-Free Battery 1 - POSITIVE POST 2 - VENT 3 - CELL CAP 4 - VENT 5 - CELL CAP 6 - VENT 7 - NEGATIVE POST 8 - INDICATOR EYE (if equipped) 9 - ELECTROLYTE LEVEL 10 - PLATE GROUPS 11 - MAINTENANCE-FREE BATTERY Fig. 5 BATTERY CELL CAP REMOVAL/ INSTALLATION - LOW-MAINTANANCE GASOLINE ENGINE BATTERY 1 - BATTERY CELL CAP 2 - BATTERY CASE Low-maintenance batteries are used on vehicles equipped with a gasoline engine, these batteries have removable battery cell caps (Fig. 5). Water can be added to this battery. Under normal service, the composition of this battery reduces gassing and water loss at normal charge rates. However these batteries may require additional distilled water after years of service. Maintenance-free batteries are standard factory-installed equipment on this model. Male post type This battery is designed to provide a safe, efficient and reliable means of storing electrical energy in a chemical form. This means of energy storage allows the battery to produce the electrical energy required to operate the engine starting system, as well as to operate many of the other vehicle accessory systems for limited durations while the engine and/or the charging system are not operating. The battery is made up of six individual cells that are connected in series. Each cell contains positively charged plate groups that are connected with lead straps to the positive terminal post, and negatively charged plate groups that are connected with lead straps to the negative terminal post. Each plate consists of a stiff mesh framework or grid coated with lead dioxide (positive plate) or sponge lead (negative plate). Insulators or plate separators made of a non-conductive material are inserted between the positive and nega- RG BATTERY SYSTEM 8Fa - 9 BATTERY (Continued) tive plates to prevent them from contacting or shorting against one another. These dissimilar metal plates are submerged in a sulfuric acid and water solution called an electrolyte. Some factory-installed batteries have a built-in test indicator (hydrometer). The color visible in the sight glass of the indicator will reveal the battery condition. For more information on the use of the built-in test indicator, refer to Standard Procedures The chemical composition of the metal coated plates within the low-maintenance battery reduces battery gassing and water loss, at normal charge and discharge rates. Therefore, the battery should not require additional water in normal service. If the electrolyte level in this battery does become low, distilled water must be added. However, rapid loss of electrolyte can be caused by an overcharging condition. Be certain to diagnose the charging system after replenishing the water in the battery for a low electrolyte condition and before returning the vehicle to service. Refer to Charging System for additional information. The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment specification for the vehicle being serviced. Refer to Battery Specifications in this group for the location of the proper factory-installed battery specifications. OPERATION The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electrical current from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. The sulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly change to lead sulfate. At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, causing the electrolyte to become mainly water. The chemical changes within the battery are caused by the movement of excess or free electrons between the positive and negative plate groups. This movement of electrons produces a flow of electrical current through the load device attached to the battery terminals. As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage potential of each cell is reduced. However, by charging the battery with a voltage higher than that of the battery itself, the battery discharging process is reversed. Charging the battery gradually changes the sulfated lead plates back into sponge lead and lead dioxide, and the water back into sulfuric acid. This action restores the difference in the electron charges deposited on the plates, and the voltage potential of the battery cells. For a battery to remain useful, it must be able to produce high-amperage current over an extended period. A battery must also be able to accept a charge, so that its voltage potential may be restored. The battery is vented to release excess hydrogen gas that is created when the battery is being charged or discharged. However, even with these vents, hydrogen gas can collect in or around the battery. If hydrogen gas is exposed to flame or sparks, it may ignite. If the electrolyte level is low, the battery may arc internally and explode. If the battery is equipped with removable cell caps, add distilled water whenever the electrolyte level is below the top of the plates. If the battery cell caps cannot be removed, the battery must be replaced if the electrolyte level becomes low. DIAGNOSIS AND TESTING - BATTERY The battery must be completely charged and the terminals should be properly cleaned and inspected before diagnostic procedures are performed. Refer to Battery System Cleaning for the proper cleaning procedures, and Battery System Inspection for the proper battery inspection procedures. Refer to Standard Procedures for the proper battery charging procedures. MICRO 420 ELECTRICAL SYSTEM TESTER The Micro420 automotive battery tester is designed to help the dealership technicians diagnose the cause of a defective battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction manual is not available refer to the standard procedure in this section, which includes the directions for using the Micro420 electrical system tester. WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING OR LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. 8Fa - 10 BATTERY SYSTEM RG BATTERY (Continued) WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN. A battery that will not accept a charge is faulty, and must be replaced. Further testing is not required. A fully-charged battery must be load tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the load test, is faulty and must be replaced. NOTE: Completely discharged batteries may take several hours to accept a charge. Refer to Standard Procedures for the proper battery charging procedures. STANDARD PROCEDURE STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING Vehicles equipped with a diesel engine utilize a unique spiral plate battery. This battery has a maximum charging voltage that must be used in order to restore the battery to its full potential, failure to use the following spiral plate battery charging procedure could result in damage to the battery or personal injury. Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when: • Micro 420 electrical system tester indicates battery is OK. • Open-circuit voltage of the battery is 12.65 volts or above. • Battery passes Load Test multiple times. WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSISTBOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Do not exceed 14.4 volts while charging a battery. CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continu- ing the charging operation. Damage to the battery may result. After the battery has been charged to 12.6 volts or greater, perform a load test to determine the battery cranking capacity. Refer to Standard Procedures for the proper battery load test procedures. If the battery will endure a load test, return the battery to service. If the battery will not endure a load test, it is faulty and must be replaced. Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. Refer to Battery System Cleaning for the proper battery system cleaning procedures, and Battery System Inspection for the proper battery system inspection procedures. CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced. (1) Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Fig. 7). If the reading is below ten volts, the battery charging current will be low. It could take some time before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers. Fig. 7 Voltmeter - Typical (2) Disconnect and isolate the battery negative cable. Connect the battery charger leads. Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufac- BATTERY SYSTEM RG 8Fa - 11 BATTERY (Continued) turer of the battery charger for details on how to bypass the polarity-sensing circuitry. (3) Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner. CHARGE RATE TABLE Voltage Hours 14.4 volts maximum up to 4 hours 13.0 to 14 volts up to 8 hours 12.9 volts or less up to 16 hours CHARGING TIME REQUIRED The time required to charge a battery will vary, depending upon the following factors: • Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery. • Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage). • Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies eight amperes will require a shorter charging time. • State-Of-Charge - A completely discharged battery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the battery charges, the specific gravity of the electrolyte will gradually rise. The Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-ofcharge and the charger capacity. BATTERY CHARGING TIME TABLE Charging Amperage Open Circuit Voltage 5 Amps 8 Amps Hours Charging @ 21° C (70° F) 12.25 to 12.49 6 hours 3 hours 12.00 to 12.24 10 hours 5 hours 10.00 to 11.99 14 hours 7 hours Below 10.00 18 hours 9 hours STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING Vehicles equipped with a diesel engine utilize a unique spiral plate battery. This battery has a maximum charging voltage that must be used in order to restore the battery to its full potential, failure to use the spiral plate battery charging procedure could result in damage to the battery or personal injury. Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when: • Micro 420 electrical system tester indicates battery is OK. • Three hydrometer tests, taken at one-hour intervals, indicate no increase in the temperature-corrected specific gravity of the battery electrolyte. • Open-circuit voltage of the battery is 12.64 volts or above. WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN. 8Fa - 12 BATTERY SYSTEM RG BATTERY (Continued) WARNING: IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS, BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS. peres. Such low current may not be detectable on the ammeters built into many battery chargers. CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Do not exceed sixteen volts while charging a battery. Damage to the vehicle electrical system components may result. CAUTION: Battery electrolyte will bubble inside the battery case during normal battery charging. Electrolyte boiling or being discharged from the battery vents indicates a battery overcharging condition. Immediately reduce the charging rate or turn off the charger to evaluate the battery condition. Damage to the battery may result from overcharging. CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the charger and let the battery cool before continuing the charging operation. Damage to the battery may result. After the battery has been charged to 12.4 volts or greater, retest the battery with the micro 420 tester or perform a load test to determine the battery cranking capacity. Refer to Standard Procedures for the proper battery load test procedures. If the battery will endure a load test, return the battery to service. If the battery will not endure a load test, it is faulty and must be replaced. Clean and inspect the battery hold downs, tray, terminals, posts, and top before completing battery service. Refer to Battery System Cleaning for the proper battery system cleaning procedures, and Battery System Inspection for the proper battery system inspection procedures. CHARGING A COMPLETELY DISCHARGED BATTERY The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced. (1) Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Fig. 8). If the reading is below ten volts, the battery charging current will be low. It could take some time before the battery accepts a current greater than a few milliam- Fig. 8 Voltmeter - Typical (2) Disconnect and isolate the battery negative cable. Connect the battery charger leads. Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry. (3) Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not measurable at the end of the charging time, the battery is faulty and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner. CHARGE RATE TABLE Voltage Hours 16.0 volts maximum up to 10 min. 14.0 to 15.9 volts up to 20 min. 13.9 volts or less up to 30 min. CHARGING TIME REQUIRED The time required to charge a battery will vary, depending upon the following factors: • Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery. • Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° BATTERY SYSTEM RG 8Fa - 13 BATTERY (Continued) F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage). • Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies twenty amperes or more will require a shorter charging time. • State-Of-Charge - A completely discharged battery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the battery charges, the specific gravity of the electrolyte will gradually rise. The Conventional Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity. Fig. 9 Testing Open-Circuit Voltage - Typical greater, it may be load tested to reveal its cranking capacity. Refer to Standard Procedures for the proper battery load test procedures. OPEN CIRCUIT VOLTAGE TABLE CONVENTIONAL BATTERY CHARGING TIME TABLE Charging Amperage Open Circuit Voltage 5 Amps 10 Amps 20 Amps Hours Charging @ 21° C (70° F) 12.25 to 12.49 6 hours 3 hours 1.5 hours 12.00 to 12.24 10 hours 5 hours 2.5 hours 10.00 to 11.99 14 hours 7 hours 3.5 hours Below 10.00 18 hours 9 hours 4.5 hours STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery. This test can be used if no other battery tester is available. Before proceeding with this test, completely charge the battery. Refer to Standard Procedures for the proper battery charging procedures. (1) Before measuring the open-circuit voltage, the surface charge must be removed from the battery. Turn on the headlamps for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize. (2) Disconnect and isolate both battery cables, negative cable first. (3) Using a voltmeter connected to the battery posts (see the instructions provided by the manufacturer of the voltmeter), measure the open-circuit voltage (Fig. 9). See the Open-Circuit Voltage Table. This voltage reading will indicate the battery state-of-charge, but will not reveal its cranking capacity. If a battery has an open-circuit voltage reading of 12.4 volts or Open Circuit Voltage Charge Percentage 11.7 volts or less 0% 12.0 volts 25% 12.2 volts 50% 12.45 volts 75% 12.65 volts or more 100% STANDARD PROCEDURE - IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. A normal vehicle electrical system will draw from five to thirty-five milliamperes (0.015 to 0.025 ampere) with the ignition switch in the Off position, and all non-ignition controlled circuits in proper working order. Up to twenty-five milliamperes are needed to enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned radio, and other modules which may vary with the vehicle equipment. A vehicle that has not been operated for approximately twenty-one days, may discharge the battery to an inadequate level. When a vehicle will not be used for twenty-one days or more (stored), remove the IOD fuse from the Integrated Power Module (IPM). This will reduce battery discharging. Excessive IOD can be caused by: • Electrical items left on. • Faulty or improperly adjusted switches. • Faulty or shorted electronic modules and components. • An internally shorted generator. 8Fa - 14 BATTERY SYSTEM RG BATTERY (Continued) • Intermittent shorts in the wiring. If the IOD is over twenty-five milliamperes, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service after the excessive IOD condition has been corrected. (1) Verify that all electrical accessories are off. Turn off all lamps, remove the ignition key, and close all doors. If the vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer function of these systems to automatically shut off (time out). This may take up to three minutes. (2) Disconnect the battery negative cable. (3) Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the disconnected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors remain closed so that the illuminated entry system is not activated. The multimeter amperage reading may remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale, depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the electronic timer function will be activated and all of the tests will have to be repeated. (4) After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or nonexistent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove and replace each fuse or circuit breaker in the Integrated Power Module (IPM), one at a time until the amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring information in this service manual for complete Integrated Power Module fuse, circuit breaker, and circuit identification. This will isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains high after removing and replacing each fuse and circuit breaker, disconnect the wire harness from the generator. If the amperage reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diagnosis and testing procedures. After the high-amperage IOD has been corrected, switch the multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of the multi-meter to check the low-amperage IOD. CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged. (5) Allow twenty minutes for the IOD to stabilize and observe the multi-meter reading. The low-amperage IOD should not exceed twenty-five milliamperes (0.025 ampere). If the current draw exceeds twentyfive milliamperes, isolate each circuit using the fuse and circuit breaker remove-and-replace process in Step 4. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL The following procedure can be used to check the electrolyte level in a low-maintenance lead-acid battery. (1) Unscrew and remove the battery cell caps with a flat-bladed screw driver (Fig. 10). Fig. 10 BATTERY CELL CAP REMOVAL/ INSTALLATION - LOW-MAINTENANCE BATTERY ONLY 1 - BATTERY CELL CAP 2 - BATTERY CASE WARNING: NEVER PUT YOUR FACE NEAR A GASSING, HOT OR SWELLED BATTERY. SERIOUS PERSONAL INJURY MAY RESULT. BATTERY SYSTEM RG 8Fa - 15 BATTERY (Continued) (2) Wearing safety glasses, look through the battery cell cap holes to determine the level of the electrolyte in the battery. The electrolyte should be above the hooks inside the battery cells (Fig. 11). Fig. 12 BATTERY POSITION & ORIENTATION 1 - BATTERY THERMOWRAP (IF EQUIPPED) 2 - INTEGRATED POWER MODULE 3 - FRONT CONTROL MODULE Fig. 11 HOOK INSIDE BATTERY CELLS - LOWMAINTENANCE BATTERY ONLY 1 - TOP OF BATTERY 2 - HOOK INSIDE BATTERY CELLS (3) Add only distilled water until the electrolyte is above the hooks inside the battery cells (Fig. 11). (2) Install the battery hold down bracket and retaining nut. Torque the nut to 20 N·m (180 in. lbs.). (3) Connect the battery cables to the battery posts, positive cable first. Torque terminal fasteners to 8.5 N·m (75 in. lbs.). REMOVAL - BATTERY BATTERY HOLDDOWN WARNING: A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES AND SAFETY GLASSES SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. DESCRIPTION (1) Verify that the ignition switch and all accessories are OFF. (2) Disconnect the battery cables from the battery posts, negative first (Fig. 12). (3) Remove the battery hold down retaining nut. (4) Remove the battery hold down bracket. (5) Remove the battery from the vehicle. The battery hold down hardware consists of a molded plastic lip that is integral to the outboard edge of the battery tray and support unit, a molded steel hold down bracket and a single hex nut with a coned washer. When installing a battery into the battery tray, be certain that the hold down hardware is properly installed and that the fasteners are tightened to the proper specifications. Improper hold down fastener tightness, whether too loose or too tight, can result in damage to the battery, the vehicle or both. Refer to Battery Hold Downs in this section of this service manual for the location of the proper battery hold down installation procedures, including the proper hold down fastener tightness specifications. INSTALLATION OPERATION WARNING: REMOVE METALLIC JEWELRY TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. (1) Position the battery in the battery tray. The battery holddown secures the battery in the battery tray. This holddown is designed to prevent 8Fa - 16 BATTERY SYSTEM RG BATTERY HOLDDOWN (Continued) battery movement during the most extreme vehicle operation conditions. Periodic removal and lubrication of the battery holddown hardware is recommended to prevent hardware seizure at a later date. NOTE: Never operate a vehicle without a battery holddown device properly installed. Damage to the vehicle, components and battery could result. REMOVAL All of the battery hold down hardware can be serviced without removal of the battery or the battery tray and support unit. (1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. (2) Remove the nut with washer that secures the battery hold down bracket to the battery tray and support unit. (3) Remove the battery hold down bracket from the battery tray and support unit. INSTALLATION (1) Install the battery hold down bracket in the battery tray and support unit. (2) Install the nut with washer that secures the battery hold down bracket to the battery tray and support unit. Torque to 20 N·m (180 in. lbs.). BATTERY CABLES 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. Refer to Wiring Diagrams in the index of this service manual for the location of the proper battery cable wire gauge information. A clamping type female battery terminal made of stamped metal is attached to one end of the battery cable wire. A square headed pinch-bolt and hex 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 solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. The battery cables cannot be repaired and, if damaged or faulty they must be replaced. 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 models. Refer to Wiring Diagrams in the index of this service manual for the location of more information on the various wiring circuits included in the battery wire harness for the vehicle being serviced. 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. The battery positive cable terminal clamp is attached to the ends of two wires. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Integrated Power Module (IPM), 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 is also attached to the ends of two wires. One wire has an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a stud on the left side of the engine cylinder block. The other wire has an eyelet terminal that connects the battery negative cable to the vehicle body through a ground screw on the left front fender inner shield, near the battery. DIAGNOSIS AND TESTING - BATTERY CABLE 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. EXAM- BATTERY SYSTEM RG 8Fa - 17 BATTERY CABLES (Continued) PLE: 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 is located in the Intelligent Power Module (IPM), in the engine compartment. See the fuse and relay layout label affixed to the underside of the IPM cover for ASD relay identification and location. (1) Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp (Fig. 13). 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 to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp (Fig. 14). 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 to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud (Fig. 15). 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 con- Fig. 13 TEST BATTERY NEGATIVE CONNECTION RESISTANCE - TYPICAL 1 - VOLTMETER 2 - BATTERY Fig. 14 TEST BATTERY POSITIVE CONNECTION RESISTANCE - TYPICAL 1 - VOLTMETER 2 - BATTERY nection 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 to measure between the battery negative cable terminal clamp and a good clean ground on the engine block (Fig. 16). 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. 8Fa - 18 BATTERY SYSTEM RG BATTERY CABLES (Continued) (3) Remove the battery thermowrap (if equipped) from the battery tray. (4) Remove the tape from the engine wire harness assembly, to access the desired battery cable. (5) One at a time, trace and disconnect the battery cable retaining fasteners and routing clips until the desired cable is free from the vehicle. (6) Feed the battery cable out of the vehicle. INSTALLATION Fig. 15 TEST BATTERY POSITIVE CABLE RESISTANCE - TYPICAL 1 - BATTERY 2 - VOLTMETER 3 - STARTER MOTOR (1) Position the battery cable in the vehicle. (2) One at a time, trace and install the battery cable retaining fasteners and routing clips until the desired cable is properly installed in the engine wire harness assembly. (3) Install the tape on the engine wire harness assembly. (4) Install the battery thermowrap (if equipped) on the battery tray. (5) Connect the negative battery cable terminal. BATTERY TRAY DESCRIPTION Fig. 16 TEST GROUND CIRCUIT RESISTANCE TYPICAL 1 - VOLTMETER 2 - BATTERY 3 - ENGINE GROUND REMOVAL The battery cables on this model may include portions of wiring circuits for the generator and other components on the vehicle. If battery cable replacement is required, it will be necessary to extract the cables out of the engine wire harness assembly. Use care not to damage the other wires and circuits which are also packaged into the engine wire harness assembly. (1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. (2) Disconnect and isolate the negative battery cable terminal. Fig. 17 RS BATTERY TRAY 1 - ENGINE VACUUM RESERVOIR 2 - BATTERY TRAY ASSEMBLY 3 - DRAINAGE HOSE The battery is mounted in a molded plastic battery tray and support unit located in the left front corner of the engine compartment. The battery tray and support unit is secured with two nuts, one is located BATTERY SYSTEM RG 8Fa - 19 BATTERY TRAY (Continued) directly under the battery and the other is located on the right side of the tray which also serves as a coolant bottle neck retaining bolt. An additional bolt is located directly under the battery. The battery tray and support unit also includes a engine vacuum reservoir, located in the rear of the unit (Fig. 17). And a drainage hose, located in the front of the unit (Fig. 17). OPERATION The battery tray provides a secure mounting location and supports the battery. The battery tray also provides the anchor point for the battery holddown hardware. The battery tray and the battery holddown hardware combine to secure and stabilize the battery in the engine compartment, which prevents battery movement during vehicle operation. Unrestrained battery movement during vehicle operation could result in damage to the vehicle, the battery, or both. The battery tray used on this model also includes a engine vacuum reservoir and drainage hose. The vacuum reservoir provides a storage container for engine vacuum. Refer to the engine section of the service manual for more engine vacuum information. The drainage hose provides means for any liquid that might collect in the bottom of the battery tray to drain under the vehicle. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the battery from the vehicle. Refer to the procedure in this section. (3) Remove the battery tray retaining fasteners (Fig. 18). (4) Pull battery tray up far enough to disconnect the engine vacuum harness hose from the battery tray mounted, vacuum reservoir. (5) Remove the battery tray from the vehicle. INSTALLATION (1) Position the battery tray in the vehicle. (2) Connect the engine vacuum harness hose on the battery tray mounted vacuum reservoir. (3) Position drainage hose and install the battery tray retaining fasteners (Fig. 18). (4) Install the battery in the vehicle. Refer to the procedure in this section. (5) Connect the negative battery cable. Fig. 18 BATTERY TRAY POSITION & ORIENTATION 1 - BATTERY TRAY RETAINING FASTENERS THERMOWRAP DESCRIPTION A one-piece slip-on thermowrap unit shields the battery case from engine compartment heat. The thermowrap slips over the battery case and due to its one piece design, the battery cables must be removed in order to install or remove the thermowrap. OPERATION The thermowrap protects the battery from engine compartment temperature extremes. The temperature of the battery can affect battery life. The air trapped in the padded material of the thermowrap creates a dead air space, which helps to insulate the sides of the battery case from the air temperature found in the surrounding engine compartment. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Disconnect the positive battery cable. (3) Lift the battery thermowrap straight up to remove from the battery. INSTALLATION (1) Position the thermowrap on the battery. (2) Connect the negative and positive battery cables. 8Fa - 20 CHARGING RG CHARGING TABLE OF CONTENTS page CHARGING DESCRIPTION - CHARGING SYSTEM . OPERATION - CHARGING SYSTEM . . . DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . . . SPECIFICATIONS GENERATOR .................. TORQUE . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS ................. BATTERY TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . GENERATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . 20 . . . . . . 21 . . . . . . 22 . . . . . . 22 . . . . . . 22 . . . . . . 23 . . . . . . 23 . . . . . . 23 . . . . . . 23 . . . . . . 23 . . . . . . 23 CHARGING DESCRIPTION - CHARGING SYSTEM The charging system consists of: • Generator • Decoupler Pulley (If equipped) • Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM) • Ignition switch (refer to the Ignition System section for information) • Battery (refer to the Battery section for information) • Inlet Air Temperature (calculated battery temperature) • Voltmeter (refer to the Instrument Cluster section for information if equipped) • Wiring harness and connections (refer to the Wiring section for information) • Accessory drive belt (refer to the Cooling section for more information) OPERATION - CHARGING SYSTEM The charging system is turned on and off with the ignition switch. The system is on when the engine is running and the ASD relay is energized. The ASD relay is energized when the PCM grounds the ASD control circuit. This voltage is connected through the PCM or IPM (intelligent power module) (if equipped) page REMOVAL - 2.5L . . . . . . . . . . . . . . . . . REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . REMOVAL - 3.5L . . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION - 2.4L ............. INSTALLATION - 2.5L ............. INSTALLATION - 3.3/3.8L . . . . . . . . . . . INSTALLATION - 3.5L ............. GENERATOR DECOUPLER PULLEY DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . VOLTAGE REGULATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . 25 . . . . . 26 . . . . . . . . . . . . . . . . . 27 . 28 . 28 . 28 . . . . . 28 . . . . . 28 . . . . . 29 . . . . . 29 . . . . . 30 . . . . . 30 . . . . . 30 and supplied to one of the generator field terminals (Gen. Source +) at the back of the generator. The generator is driven by the engine through a serpentine belt and pulley or decoupler pulley arrangement. The amount of DC current produced by the generator is controlled by the EVR (field control) circuitry contained within the PCM. This circuitry is connected in series with the second rotor field terminal and ground. An Inlet air temperature sensor is used to calculate the temperature near the battery. This temperature data, along with data from monitored line voltage (battery voltage sense circuit), is used by the PCM to vary the battery charging rate. This is done by cycling the ground path to control the strength of the rotor magnetic field. The PCM then compensates and regulates generator current output accordingly to maintain system voltage at the targeted system voltage based on battery temperature. All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including EVR (field control) circuitry, are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects and illuminate the (MIL) lamp. Refer to On-Board Diagnostics in the Electronic Control Modules(Refer to 8 ELECTRICAL/ELECTRONIC CONTROL MOD- RG CHARGING 8Fa - 21 CHARGING (Continued) ULES/POWERTRAIN CONTROL MODULE DESCRIPTION) section for more DTC information. The Check Gauges Lamp (if equipped) or Battery Lamp monitors: charging system voltage, engine coolant temperature and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. The signal to activate the lamp is sent via the PCI bus circuits. The lamp is located on the instrument panel. Refer to the Instrument Cluster section for additional information. The PCM uses the inlet air temperature sensor to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as the calculated battery temperature increases. The ambient temperature sensor is used to control the battery voltage based upon ambient temperature (approximation of battery temperature). The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the OBD system. Some circuits are checked continuously and some are checked only under certain conditions. If the OBD system senses that a monitored circuit is bad, it will put a DTC into electronic memory. The DTC will stay in electronic memory as long as the circuit continues to be bad. The PCM is programmed to clear the memory after 50 engine starts if the problem does not occur again. DIAGNOSTIC TROUBLE CODES A DTC description can be read using the DRBIIIt scan tool. Refer to the appropriate Powertrain Diagnostic Procedures manual for information. A DTC does not identify which component in a circuit is bad. Thus, a DTC should be treated as a symptom, not as the cause for the problem. In some cases, because of the design of the diagnostic test procedure, a DTC can be the reason for another DTC to be set. Therefore, it is important that the test procedures be followed in sequence, to understand what caused a DTC to be set. ERASING DIAGNOSTIC TROUBLE CODES The DRBIIIt Scan Tool must be used to erase a DTC. The following procedures may be used to diagnose the charging system if: • the check gauges lamp or battery lamp is illuminated with the engine running • the voltmeter (if equipped) does not register properly • an undercharged or overcharged battery condition occurs. Remember that an undercharged battery is often caused by: • accessories being left on with the engine not running • a faulty or improperly adjusted switch that allows a lamp to stay on. Refer to Ignition-Off Draw Test (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ BATTERY - STANDARD PROCEDURE) INSPECTION The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored by the On-Board Diagnostic (OBD) system. Some charging system circuits are checked continuously, and some are checked only under certain conditions. Refer to Diagnostic Trouble Codes in; Powertrain Control Module; Electronic Control Modules for more DTC information. This will include a complete list of DTC’s including DTC’s for the charging system. To perform a complete test of the charging system, refer to the appropriate Powertrain Diagnostic Procedures service manual and the DRBIIIt scan tool. Perform the following inspections before attaching the scan tool. (1) Inspect the battery condition. Refer to the Battery section (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) for procedures. (2) Inspect condition of battery cable terminals, battery posts, connections at engine block, starter solenoid and relay. They should be clean and tight. Repair as required. (3) Inspect all fuses in both the fuseblock and Power Distribution Center (PDC) for tightness in receptacles. They should be properly installed and tight. Repair or replace as required. (4) Inspect generator mounting bolts for tightness. Replace or tighten bolts if required. Refer to the Generator Removal/Installation section of this group for torque specifications (Refer to 8 - ELECTRICAL/ CHARGING - SPECIFICATIONS). 8Fa - 22 CHARGING RG CHARGING (Continued) (5) Inspect generator drive belt condition and tension. Tighten or replace belt as required. Refer to Belt Tension Specifications(Refer to 7 - COOLING/ ACCESSORY DRIVE - SPECIFICATIONS). (6) Inspect decoupler pulley (if equipped). Ensure decoupler pulley is driving the alternator rotor. (7) Inspect automatic belt tensioner (if equipped). Refer to the Cooling System for more information. (8) Inspect generator electrical connections at generator field, battery output, and ground terminal (if equipped). Also check generator ground wire connection at engine (if equipped). They should all be clean and tight. Repair as required. SPECIFICATIONS GENERATOR Type Engine Minimun Test Amperage Denso 2.4 L 125 Amp Denso 3.3/3.8L 135 Amp or 145 Amp Test Specification: 1. Engine RPM : 2500 RPM ±20 RPM 2. Voltage Output : 14.0 V ± 0.5 V 3. Field Current : 5 amps ± 0.1 amps Part number is located on the side of the generator. TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Battery Hold Down Clamp Bolt 20 14.7 180 Generator B+ Nut 12.4 9.2 110 Battery Terminal Nut 4 Generator Mounting Bolt 2.4L 28.2 20.8 Generator Mounting Bolts 3.3/3.8L 54.2 40 Starter Solenoid Battery Nut 3.3/3.8L 11.3 8.3 Generator Decoupler 109.8 81 SPECIAL TOOLS GENERATOR DECOUPLER 8433 35 250 100 CHARGING RG BATTERY TEMPERATURE SENSOR DESCRIPTION The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. OPERATION The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. The ambient temperature sensor is used to control the battery voltage based upon ambient temperature (approximation of battery temperature). The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. GENERATOR DESCRIPTION The generator is belt-driven by the engine. It is serviced only as a complete assembly. The generator produces DC voltage at the B+ terminal. If the generator is failed, the generator assembly subcomponents (generator and decoupler pulley) must be inspected for individual failure and replaced accordingly. 8Fa - 23 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. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. 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. Excessive or abnormal noise emitting from the generator may be caused by: • Worn, loose or defective bearings • Loose or defective drive pulley (2.4L) or decoupler (3.3/3.8L) • Incorrect, worn, damaged or misadjusted drive belt • Loose mounting bolts • Misaligned drive pulley • Defective stator or diode • Damaged internal fins REMOVAL REMOVAL - 2.4L (1) Release hood latch and open hood. (2) Disconnect battery negative cable. (3) Disconnect the Inlet Air Temperature sensor. (4) Remove the Air Box, refer to the Engine/Air Cleaner for more information. (5) Remove the EVAP Purge solenoid from its bracket and reposition. (6) Disconnect the push-in field wire connector from back of generator. (7) Remove nut holding B+ wire terminal to back of generator. (8) Separate B+ terminal from generator. (9) Remove accessory drive belt, refer to the Cooling System section for proper procedures. (10) Remove the generator. 8Fa - 24 CHARGING RG GENERATOR (Continued) REMOVAL - 2.5L (1) Disconnect the negative battery cable (Fig. 1). Fig. 1 BATTERY CONNECTION (2) Remove the engine cover (Fig. 2). Fig. 2 ENGINE COVER (3) Raise vehicle and support. (4) Turn wheels to the right. Remove the right front splash shield (Fig. 3). Fig. 3 SPLASH SHIELD (5) Remove the generator drive belt (Fig. 4). Fig. 4 GENERATOR BELT CHARGING RG 8Fa - 25 GENERATOR (Continued) (6) Lower vehicle. (7) Disconnect the generator battery connection (Fig. 5). Fig. 7 AIR BOX REMOVED Fig. 5 GENERATOR CONNECTIONS 1 - Battery Connection 2 - Field Connection (8) Disconnect the field connection (Fig. 5). (9) Relocate the wiring harness on upper generator bracket (Fig. 6). Fig. 8 GENERATOR LOWER BOLTS 1 - Lower Mounting Bolts REMOVAL - 3.3/3.8L Fig. 6 UPPER SUPPORT BRACKET 1 - Wiring Harness 2 - Upper Bracket (10) Remove the Air Cleaner Box (Fig. 7). (11) Remove the 2 lower mounting Bolts (Fig. 8). (12) Remove generator. (1) Release hood latch and open hood. (2) Disconnect battery negative cable. (3) Disconnect the push-in field wire connector from back of generator. (4) Remove nut holding B+ wire terminal to back of generator. (5) Separate B+ terminal from generator. (6) Raise vehicle and support. (7) Remove the right front lower splash shield. (8) Remove accessory drive belt, refer to the Cooling System section for proper procedures. 8Fa - 26 CHARGING RG GENERATOR (Continued) (9) Remove the lower oil dip stick tube bolt (Fig. 9). (10) Remove wiring harness from the oil dip stick tube REMOVAL - 3.5L (1) Disconnect the negative battery cable. (2) Turn wheels to the right. (3) Raise and support the vehicle. (4) Remove the right front tire. (5) Remove the front axle nut. (6) Relocate the ABS sensor (Fig. 11) wiring from bracket (Fig. 12). Fig. 9 DIP STICK LOWER BOLT (11) Remove the 3 mounting bolts. (12) Lower vehicle. (13) Remove oil dip stick tube from vehicle. (14) Roll and remove the generator from vehicle (Fig. 10). Fig. 11 ABS WIRING AND STRUT Fig. 12 ABS WIRING AND STRUT Fig. 10 GENERATOR 3.3/3.8L CHARGING RG 8Fa - 27 GENERATOR (Continued) (7) Remove the 2 upper clevies bolts. (8) Remove axle from knuckle (Fig. 13). Fig. 15 GENERATOR CONNECTORS (9) Remove the right front splash shield. (10) Remove the accessory drive belt (Fig. 14), refer to the cooling section. (13) Disconnect the field connector. (14) Remove the axle from vehicle, oil will leak from transmission. (15) Remove the 3 mounting bolts for generator. (16) Remove generator from vehicle (Fig. 16). Fig. 14 ACCESSORY DRIVE BELT Fig. 16 GENERATOR REMOVEL/INSTALLATION Fig. 13 AXLE AND KNUCKLE (11) Disconnect the generator positive battery cable. (12) Unlock the electrical connector for the field connector (Fig. 15). INSTALLATION INSTALLATION - 2.4L (1) Install the generator. (2) Install the accessory drive belt, refer to the Cooling System section for proper procedures. (3) Connect B+ terminal to generator. (4) Install nut holding B+ wire terminal to back of generator. 8Fa - 28 CHARGING RG GENERATOR (Continued) (5) Connect the push-in field wire connector to back of generator. (6) Install the EVAP Purge solenoid to its bracket. (7) Install the Air Box, refer to the Engine/Air Cleaner for more information. (8) Connect the Inlet Air Temperature sensor. (9) Connect battery negative cable. INSTALLATION - 2.5L (1) Install generator. (2) Install the 2 lower mounting Bolts (Fig. 8). (3) Install the Air Cleaner Box (Fig. 7). (4) Install the upper support bracket (Fig. 6). (5) Install the wiring harness on upper generator bracket (Fig. 6). (6) Connect the field connection (Fig. 5). (7) Connect the generator battery connection (Fig. 5). (8) Raise vehicle and support. (9) Install the generator drive belt (Fig. 4). (10) Install the right front splash shield (Fig. 3). (11) Lower vehicle. (12) Install the engine cover (Fig. 2). (13) Connect the negative battery cable (Fig. 1). INSTALLATION - 3.3/3.8L (1) Roll and place generator in position on vehicle (Fig. 10). (2) Install upper bolts to hold generator in place. (3) Lubricate the o-ring. Install oil dip stick tube. (4) Install the upper oil dip stick tube bolt. (5) Place B+ terminal in position on generator. (6) Install nut to hold B+ wire terminal to back of generator. (7) Connect the push-in field wire connector into back of generator. (8) Raise vehicle and support. (9) Install the lower mounting bolt and tighten. (10) Install the lower oil dip stick tube bolt and tighten (Fig. 9). (11) Install accessory drive belt, refer to the Cooling System section for proper procedures. (12) Install the right front lower splash shield. (13) Lower vehicle. (14) Install wiring harness to the oil dip stick tube (15) Connect battery negative cable. (16) Verify generator output rate. INSTALLATION - 3.5L (1) Install generator (Fig. 16) and the 3 mounting bolts and tighten. (2) Connect the generator positive battery cable (Fig. 15). (3) Connect the field connector and lock the connector (Fig. 15). (4) Install the axle shaft to the transmission. (5) Install axle to steering knuckle (Fig. 13). (6) Install the 2 upper clevies bolts and tighten, refer to the Suspension section. (7) Install axle nut and tighten, refer to the Differential and Driveline section. (8) Relocate the ABS sensor wiring to bracket (Fig. 12). (9) Install the accessory drive belt (Fig. 14), refer to the Cooling section. (10) Install the right front splash shield. (11) Install the right front tire, refer to the Wheels and Tires section. (12) Lower vehicle. (13) Connect the negative battery cable. GENERATOR DECOUPLER PULLEY DESCRIPTION The Generator Decoupler is a one way clutch (Fig. 17). It is attached to the generator and replaces the standard pulley. It is a non-serviceable item and is to be replaced as an assembly. It is a dry operation (no grease or lubricants). The operation of it is not temperature sensitive and has a low sensitivity to electrical load. Fig. 17 GENERATOR DECOUPLER 3.3/3.8L OPERATION The generator decoupler is a one way clutch and should be replaced as an assembly. It is designed to help reduce belt tension fluctuation, reduce fatigue loads, improve belt life, reduce hubloads on components, and reduce noise. CHARGING RG 8Fa - 29 GENERATOR DECOUPLER PULLEY (Continued) DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY CONDITION Does not drive generator (Generator not Charging) POSSIBLE CAUSES Clutch failure CORRECTION Replace Decoupler REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable. (3) Raise vehicle and support. (4) Remove the right front lower splash shield. (5) Remove accessory drive belt, refer to the Cooling System section for proper procedures (Fig. 18). Fig. 19 DECOUPLER REMOVAL (LITENS) Fig. 18 DRIVE BELT 3.3/3.8L (6) Lower vehicle. (7) Remove the Air Box, refer to the Engine section for more information. (8) Use Special Tool #8433 (Fig. 20) to loosen the Generator Decoupler (Fig. 19). (9) Remove the tool. (10) Remove the Generator Decoupler. Fig. 20 SPECIAL TOOL 8433 AND DECOUPLER 8Fa - 30 CHARGING RG GENERATOR DECOUPLER PULLEY (Continued) INSTALLATION (1) Install the Generator Decoupler to the generator shaft. (2) Use Special Tool #8433 (Fig. 20) to tighten the Generator Decoupler (Fig. 21). Refer to the torque chart for the proper torque. VOLTAGE REGULATOR DESCRIPTION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. OPERATION Fig. 21 DECOUPLER INSTALLATION (Litens) (3) Install the Air Box, refer to the Engine section for more information. (4) Raise vehicle and support. (5) Install accessory drive belt, refer to the Cooling System section for proper procedures (Fig. 18). (6) Install the right front lower splash shield. (7) Lower vehicle. (8) Connect battery negative cable. The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and calculated battery temperature or inlet air temperature sensor (refer to Inlet Air Temperature Sensor, if equipped, for more information ). It then determines a target charging voltage. If sensed battery voltage is lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is at the target voltage. A circuit in the PCM cycles the ground side of the generator field at 250 times per second (250Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information. STARTING RG 8Fa - 31 STARTING TABLE OF CONTENTS page STARTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - STARTING SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . 31 . . 31 . . 34 . . 36 . . 36 page Torques . . . . . . . . . . . . STARTER MOTOR REMOVAL REMOVAL - 2.4L . . . . . REMOVAL - 3.3/3.8L . . REMOVAL - 3.5L . . . . . REMOVAL - 2.5L . . . . . INSTALLATION INSTALLATION - 2.4L . INSTALLATION - 3.3/3.8L INSTALLATION - 3.5L . INSTALLATION - 2.5L . . . . . . . . . . . . . . . . . . 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 . 39 . 39 . 40 .. . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . 41 . 41 . 41 . . 37 STARTING DIAGNOSIS AND TESTING DESCRIPTION DIAGNOSIS AND TESTING - STARTING SYSTEM TEST The starting system has (Fig. 1): • Ignition switch • Starter relay • Transmission Range Sensor or Park/Neutral Switch • Wiring harness • Battery • Starter motor with an integral solenoid • Powertrain Control Module (PCM) OPERATION These components form two separate circuits. A high amperage circuit that feeds the starter motor up to 300+ amps, and a control circuit that operates on less than 20 amps. The PCM controls a double start over-ride safety that does not allow the starter to be engaged if the engine is already running. For circuit descriptions and diagrams, refer to the Wiring Diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO THE PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING 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. 8Fa - 32 STARTING RG STARTING (Continued) INSPECTION Fig. 1 STARTING SYSTEM SCHEMATIC 1 - SOLENOID TERMINAL 2 - STARTER SOLENOID 3 - STARTER MOTOR 4 - STARTER RELAY CONNECTOR 5 - PCM 6 - GROUND CIRCUIT 7 - TRANSMISSION RANGE SENSOR/PARK/NEUTRAL SENSE 8 - IGNITION SWITCH 9 - IGNITION FEED 10 - BATTERY 11 - BATTERY RELAY FEED 12 - POSITIVE CABLE 13 - NEGATIVE CABLE 14 - CLUTCH INTERLOCK SWITCH (MTX ONLY) Before removing any unit from the starting system for repair or diagnosis, perform the following inspections: • Battery - Visually inspect the battery for indications of physical damage and loose or corroded cable connections. Determine the state-of-charge and cranking capacity of the battery. Charge or replace the battery, if required. Refer to the Battery section for more information. • Ignition Switch - Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness connections. • Transmission Range Sensor - Visually inspect the transmission range sensor for indications of physical damage and loose or corroded wire harness connections. • Starter Relay - Visually inspect the starter relay for indications of physical damage and loose or corroded wire harness connections. • Starter - Visually inspect the starter for indications of physical damage and loose or corroded wire harness connections. • Starter Solenoid - Visually inspect the starter solenoid for indications of physical damage and loose or corroded wire harness connections. • Wiring - Visually inspect the wire harness for damage. Repair or replace any faulty wiring, as required. Check for loose or corroded wire harness connections at main engine ground and remote jump post. • Power Distribution Center (PDC) - Visually inspect the B+ connections at the PDC for physical damage and loose or corroded harness connections. STARTING RG 8Fa - 33 STARTING (Continued) STARTING SYSTEM DIAGNOSIS CONDITION STARTER FAILS TO ENGAGE. STARTER ENGAGES, FAILS TO TURN ENGINE. POSSIBLE CAUSE CORRECTION 1. BATTERY DISCHARGED OR FAULTY. 1. REFER TO THE BATTERY SECTION FOR MORE INFORMATION. CHARGE OR REPLACE BATTERY, IF REQUIRED. 2. STARTING CIRCUIT WIRING FAULTY. 2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED CIRCUIT TEST IN THIS SECTION. 3. STARTER RELAY FAULTY. 3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE RELAY, IF NECESSARY. 4. IGNITION SWITCH FAULTY. 4. REFER TO IGNITION SWITCH TEST, IN THE STEERING SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF NECESSARY. 5. PARK/NEUTRAL POSITION SWITCH (AUTO TRANS) FAULTY OR MIS-ADJUSTED. 5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE SWITCH, IF NECESSARY. 6. CLUTCH PEDAL POSITION SWITCH (MAN TRANS) FAULTY. 6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY. 7. STARTER SOLENOID FAULTY. 7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE STARTER ASSEMBLY, IF NECESSARY. 8. STARTER ASSEMBLY FAULTY. 8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY. 9. FAULTY TEETH ON RING GEAR. 9. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED. 10. PCM DOUBLE START OVERRIDE OUTPUT FAILURE. 10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE. 1. BATTERY DISCHARGED OR FAULTY. 1. REFER TO THE BATTERY SECTION FOR MORE INFORMATION. CHARGE OR REPLACE BATTERY AS NECESSARY. 2. STARTING CIRCUIT WIRING FAULTY. 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS NECESSARY. 3. STARTER ASSEMBLY FAULTY. 3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY. 4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND SERVICE PROCEDURES. 5. LOOSE CONNECTION AT BATTERY, PDC, STARTER, OR ENGINE GROUND. 5. INSPECT FOR LOOSE CONNECTIONS. 6. FAULTY TEETH ON RING GEAR. 6. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED. 8Fa - 34 STARTING RG STARTING (Continued) CONDITION STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS. STARTER DOES NOT DISENGAGE. POSSIBLE CAUSE CORRECTION 1. BROKEN TEETH ON STARTER RING GEAR. 1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE IF NECESSARY. 2. STARTER ASSEMBLY FAULTY. 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY. 1. STARTER IMPROPERLY INSTALLED. 1. INSTALL STARTER. TIGHTEN STARTER MOUNTING HARDWARE TO CORRECT TORQUE SPECIFICATIONS. 2. STARTER RELAY FAULTY. 2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE RELAY, IF NECESSARY. 3. IGNITION SWITCH FAULTY. 3. REFER TO IGNITION SWITCH TEST, IN THE STEERING SECTION. REPLACE SWITCH, IF NECESSARY. 4. STARTER ASSEMBLY FAULTY. 4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY. 5. FAULTY TEETH ON RING GEAR. 5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING GEAR REPLACED IF DAMAGED. DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST • To disable ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for the proper relay location. (3) Perform a visual inspection of the starter/ starter solenoid for corrosion, loose connections or faulty wiring. (4) Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. (5) Connect a remote starter switch or a jumper wire between the remote battery positive post and terminal 87 of the starter relay connector. (a) If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test. (b) If engine does not crank or solenoid chatters, check wiring and connectors from starter relay to starter solenoid for loose or corroded connections. Particularly at starter terminals. (c) Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter. Inspect the ring gear teeth. STARTER SOLENOID STARTER RELAY WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APPLIED. WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK/NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED. The starter control circuit has: • Starter motor with integral solenoid • Starter relay • Transmission range sensor, or Park/Neutral Position switch with automatic transmissions • Ignition switch • Battery • All related wiring and connections • Powertrain Control Module (PCM) CAUTION: Before performing any starter tests, the ignition and fuel systems must be disabled. (1) Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests. Refer to Battery Tests. (2) Perform Starter Solenoid test BEFORE performing the starter relay test. RELAY TEST The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. STARTING RG 8Fa - 35 STARTING (Continued) Remove the starter relay from the PDC as described in this group to perform the following tests: (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. (2) Resistance between terminals 85 and 86 (electromagnet) should be 75 ±5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. (3) Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Starter Relay Pinout Starter Relay Pinout CAV FUNCTION 30 B (+) 85 P/N POSITION SW.SENSE 86 IGNITION SWITCH OUTPUT 87 STARTER RELAY OUTPUT 87A NO CONNECT RELAY CIRCUIT TEST (1) The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. (2) The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. (3) The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. (4) The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position and the clutch pedal is depressed (manual trans). Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position and the clutch pedal is depressed (manual trans), and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure in this group. (5) The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the transmission range sensor only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the transmission range sensor and repair. It is grounded by the PCM if the conditions are right to start the car. For automatic trans. cars the PCM must see Park Neutral switch and near zero engine rpm. For manual trans. cars the PCM only needs to see near zero engine rpm. To diagnose the Park Neutral switch of the trans range sensor refer to the transaxle section for more information. Check for continuity to ground while the ignition switch is in the start position. If not OK and the vehicle has an automatic trans. verify Park Neutral switch opera- 8Fa - 36 STARTING RG STARTING (Continued) tion. If that checks OK check for continuity between PCM and the terminal 85. Repair open circuit as required. If OK, the PCM may be defective. SAFETY SWITCHES For diagnostics of the Transmission Range Sensor, refer to the Transaxle section for more information. If equipped with Clutch Interlock/Upstop Switch, refer to Diagnosis and Testing in the Clutch section. IGNITION SWITCH After testing starter solenoid and relay, test ignition switch and wiring. Refer to the Ignition Section or Wiring Diagrams for more information. Check all wiring for opens or shorts, and all connectors for being loose or corroded. BATTERY For battery diagnosis and testing, refer to the Battery section for procedures. ALL RELATED WIRING AND CONNECTORS Refer to Wiring Diagrams for more information. (c) Connect negative lead of voltmeter to battery negative terminal, and positive lead to engine block near the battery cable attaching point. Rotate and hold the ignition switch in the START position. If voltage reads above 0.2 volt, correct poor contact at ground cable attaching point. If voltage reading is still above 0.2 volt after correcting poor contacts, replace ground cable. (4) Connect positive voltmeter lead to the starter motor housing and the negative lead to the battery negative terminal. Hold the ignition switch key in the START position. If voltage reads above 0.2 volt, correct poor starter to engine ground. (a) Connect the positive voltmeter lead to the battery positive terminal, and negative lead to battery cable terminal on starter solenoid. Rotate and hold the ignition switch in the START position. If voltage reads above 0.2 volt, correct poor contact at battery cable to solenoid connection. If reading is still above 0.2 volt after correcting poor contacts, replace battery positive cable. (b) If resistance tests do not detect feed circuit failures, replace the starter motor. DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST DIAGNOSIS AND TESTING - FEED CIRCUIT TEST Before proceeding with this operation, review Diagnostic Preparation and Starter Feed Circuit Tests. The following operation will require a voltmeter, accurate to 1/10 of a volt. NOTE: The following results are based upon the vehicle being at room temperature. CAUTION: Ignition and Fuel systems must be disabled to prevent engine start while performing the following tests. (1) To disable the Ignition and Fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for proper relay location. (2) Gain access to battery terminals. (3) With all wiring harnesses and components properly connected, perform the following: (a) Connect the negative lead of the voltmeter to the battery negative post, and positive lead to the battery negative cable clamp. Rotate and hold the ignition switch in the START position. Observe the voltmeter. If voltage is detected, correct poor contact between cable clamp and post. (b) Connect positive lead of the voltmeter to the battery positive post, and negative lead to the battery positive cable clamp. Rotate and hold the ignition switch key in the START position. Observe the voltmeter. If voltage is detected, correct poor contact between the cable clamp and post. The following procedure will require a suitable volt-ampere tester (Fig. 3). Fig. 3 Volt Ampere Tester CAUTION: Before performing any starter tests, the ignition and fuel systems must be disabled. (1) Check battery before performing this test. Battery must be fully charged. (2) Connect a volt-ampere tester to the battery terminals. Refer to the operating instructions provided with the tester being used. STARTING RG 8Fa - 37 STARTING (Continued) (3) To disable the ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for proper relay location. (4) Verify that all lights and accessories are OFF, and the transmission shift selector is in the PARK and SET parking brake. SPECIFICATIONS CAUTION: Do not overheat the starter motor or draw the battery voltage below 9.6 volts during cranking operations. (5) Rotate and hold the ignition switch in the START position. Observe the volt-ampere tester (Fig. 3). • If voltage reads above 9.6 volts, and amperage draw reads above 280 amps, check for engine seizing or faulty starter. • If voltage reads 12.4 volts or greater and amperage reads 0 to 10 amps, check for corroded cables and/or bad connections. • Voltage below 9.6 volts and amperage draw above 300 amps, the problem is the starter. Replace the starter refer to starter removal. (6) After the starting system problems have been corrected, verify the battery state-of-charge and charge battery if necessary. Disconnect all testing equipment and connect ASD relay. Start the vehicle several times to assure the problem has been corrected. STARTER MANUFACTURER NIPPONDENSO Engine Application 2.4L /3.3/3.8L Power rating 1.2 Kw Voltage 12 VOLTS No. of Fields 4 No. of Poles 4 Brushes 4 Drive Conventional Gear Train Free running Test Voltage 11 Amperage Draw 73 Amp Minimum Speed 3401 RPM SolenoidClosing Voltage 7.5 Volts Cranking Amperage Draw test 150 - 200 Amps. Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase starter amperage draw. Torques DESCRIPTION N·m Ft. Lbs. Starter Mounting Bolts 47.4 35 Starter Solenoid Battery Nut 11.3 8.3 In. Lbs. 100 8Fa - 38 STARTING RG STARTER MOTOR REMOVAL REMOVAL - 2.4L (1) Release hood latch and open hood (Fig. 4). Fig. 5 BATTERY CABLE AND FIELD WIRE 2.4L Fig. 4 STARTER 2.4L (2) Disconnect and isolate the battery negative cable. (3) Disconnect solenoid wire connector from terminal (Fig. 5). (4) Remove nut holding B+ wire to terminal. (5) Disconnect solenoid and B+ wires from starter terminals. (6) Remove the lower bolt. (7) Remove the upper bolt and ground wire (Fig. 6). (8) Remove starter. Fig. 6 Upper Bolt and Ground Wire STARTING RG 8Fa - 39 STARTER MOTOR (Continued) REMOVAL - 3.3/3.8L (7) Remove starter from bellhousing (Fig. 9). (1) Release hood latch and open hood. (2) Disconnect and isolate the battery negative cable. (3) Hoist and support vehicle on safety stands. (4) Remove nut holding B+ terminal to starter solenoid (Fig. 7). Fig. 9 STARTER 3.3/3.8L 1 2 3 4 5 Fig. 7 Starter 1 - SOLENOID CONNECTOR 2 - B+ CONNECTOR (5) Disconnect solenoid connector from starter. (6) Remove bolts holding starter to transaxle bellhousing (Fig. 8). - BELL HOUSING PLATE FLYWHEEL ENGINE MOUNT STARTER SPACER (8) Separate starter spacer from transaxle bellhousing. REMOVAL - 3.5L (1) (2) (3) (Fig. Disconnect the negative battery cable. Raise vehicle and support Disconnect the battery positive cable at starter 10). Fig. 8 Starter Bolts 1 2 3 4 - STARTER STARTER BOLTS TRANSAXLE ENGINE MOUNT Fig. 10 ELECTRICAL CONNECTIONS 8Fa - 40 STARTING RG STARTER MOTOR (Continued) (4) Disconnect the solenoid connector (Fig. 10). (5) Turn front wheels to the left and use long extension to reach the upper mounting bolt (Fig. 11). (9) Remove the lower mounting bolt (Fig. 13). Fig. 13 LOWER BOLT Fig. 11 STARTER BOLTS AND STUD (6) Remove the ground wires from the upper mounting bolt. (7) Remove the upper mounting bolt. (8) Remove the middle mounting bolts (Fig. 12). (10) Remove starter. REMOVAL - 2.5L (1) Disconnect the negative battery cable. (2) Raise vehicle and support. (3) Remove the lower engine splash shield. (4) Remove the electrical connectors from the starter (Fig. 14). Fig. 12 MIDDLE BOLT Fig. 14 STARTER LOCATION STARTING RG 8Fa - 41 STARTER MOTOR (Continued) (5) Remove the starter mounting bolts (Fig. 15). (8) Verify starter operation. INSTALLATION - 3.3/3.8L (1) Place starter spacer in position on transaxle bellhousing, flange toward flywheel. (2) Place starter in position on bellhousing. (3) Install bolts and ground wire (Fig. 6) to hold starter to transaxle bellhousing. (4) Connect solenoid connector into starter. (5) Install nut to hold B+ terminal to starter solenoid. (6) Lower vehicle. (7) Connect battery negative cable. (8) Verify starter operation. INSTALLATION - 3.5L Fig. 15 STARTER MOUNTING BOLTS 1 - Starter 2 - Mounting Bolts (6) Remove the starter. INSTALLATION INSTALLATION - 2.4L (1) Place starter in position on vehicle. (2) Install the lower bolts to hold starter to transaxle bellhousing. (3) Install the upper bolt and ground wire (Fig. 6). (4) Place solenoid and B+ wires in position on starter terminals (Fig. 5). (5) Install nut to hold B+ wire to terminal. (6) Connect solenoid wire connector onto terminal. (7) Connect battery negative cable. (1) Install starter. (2) Install the middle (Fig. 12) and lower (Fig. 13) mounting bolts. Turn front wheels to the left and use long extension to reach the upper mounting bolt (Fig. 11). (3) Install the upper mounting bolt. (4) Install the ground wires to the upper mounting bolt. (5) Connect the solenoid connector (Fig. 10). (6) Connect the battery positive cable at starter (Fig. 10). (7) Lower vehicle. (8) Connect the negative battery cable. INSTALLATION - 2.5L (1) (2) (3) (4) (Fig. (5) (6) (7) Raise vehicle and support. Install the starter. Install the starter mounting bolts (Fig. 15). Install the electrical connectors to the starter 14). Install the lower engine splash shield. Connect the negative battery cable. Lower vehicle. STEERING RS 19 - 1 STEERING TABLE OF CONTENTS page STEERING DESCRIPTION - POWER STEERING SYSTEM OPERATION - POWER STEERING SYSTEM DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - POWER STEERING SYSTEM FLOW AND PRESSURE TEST . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - STEERING SYSTEM DIAGNOSIS CHARTS . . . . . . . . . ..1 ...1 ...1 page SPECIFICATIONS POWER STEERING FASTENER TORQUE ...9 SPECIAL TOOLS POWER STEERING ....................9 COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ...3 STEERING DIAGNOSIS AND TESTING DESCRIPTION - POWER STEERING SYSTEM DIAGNOSIS AND TESTING - POWER STEERING SYSTEM FLOW AND PRESSURE TEST This vehicle comes with power steering as standard equipment. The power steering system consists of these major components: • POWER STEERING PUMP • POWER STEERING GEAR • POWER STEERING FLUID • POWER STEERING FLUID COOLER • POWER STEERING FLUID RESERVOIR • POWER STEERING FLUID SUPPLY HOSE • POWER STEERING FLUID PRESSURE HOSE • POWER STEERING FLUID RETURN HOSE For information on the first two components, refer to their respective sections within this service manual group. Information on all other components can be found in POWER STEERING PUMP. ALL ENGINES The following procedure is to be used to test the operation of the power steering system on this vehicle. This test will provide the flow rate of the power steering pump along with the maximum relief pressure. This test is to be performed to determine if the power steering pump or power steering gear is not functioning properly. The following flow and pressure test is performed using the Power Steering Analyzer Kit, Special Tool 6815 (Fig. 1), hoses, Special Tools 6905 and 6959, and fittings from adapter kit, Special Tool 6893. OPERATION - POWER STEERING SYSTEM Turning of the steering wheel is converted into linear (side-to-side) travel through the meshing of the helical pinion teeth with the rack teeth within the steering gear. The lateral travel pushes and pulls the tie rods to change the direction of the vehicle’s front wheels. Power assist steering is provided by a belt driven rotary type pump. It directs fluid through power steering fluid hoses to the power steering gear where it is used to assist the driver’s turning effort. Manual steering control of the vehicle can be maintained if power steering assist is lost. However, under this condition, steering effort is significantly increased. Fig. 1 Power Steering Analyzer With Hoses Installed 1 - OUTLET 2 - SPECIAL TOOL 6815 3 - INLET 19 - 2 STEERING RS STEERING (Continued) Assemble hoses on Power Steering Analyzer, Special Tool 6815, as shown. Install Pressure Hose, Special Tool 6905 (in 6893 kit), in the inlet fitting on Power Steering Analyzer. Install Pressure Hose, Special Tool 6713 (in 6815 kit) on Pressure Hose, Special Tool 6905. Install Pressure Hose, Special Tool 6959, in the outlet fitting on Power Steering Analyzer. Install the following adapters from Adapter Set, Special Tool 6893 (Fig. 2), on the analyzer hose ends: Install Adapter Fitting, Special Tool 6844, on Pressure Hose, Special Tool 6713. Install Adapter Fitting, Special Tool 6826, on Pressure Hose, Special Tool 6959. Fig. 3 Pressure Hose Connection To Power Steering Pump - 2.4L Engine 1 - POWER STEERING FLUID RETURN HOSE 2 - POWER STEERING PUMP 3 - POWER STEERING FLUID PRESSURE HOSE Fig. 2 Power Steering Analyzer Adapters 6893 CAUTION: To prevent personal injury, safety goggles should be worn at all times when performing any test procedures on the power steering pump or power steering gear. The following procedure is to be used to test the operation of the power steering system on the vehicle. (1) Check belt tension and adjust as necessary. (2) Disconnect the power steering fluid pressure hose from the power steering pump (Fig. 3) (Fig. 4). (3) Connect Adapter Fitting, Special Tool 6844, attached to pressure hose from inlet (gauge end) of Power Steering Analyzer to the pressure fitting on the power steering pump. (4) Connect vehicle power steering fluid pressure hose to Adapter Fitting, Special Tool 6826, which should be already installed in the outlet hose (valve end) of Power Steering Analyzer. Fig. 4 Supply & Pressure Hoses At Pump - 3.3L/3.8L Engine 1 - PRESSURE HOSE AND FITTING 2 - SUPPLY HOSE AND CLAMP 3 - POWER STEERING PUMP NOTE: During the next few steps, do not steer vehicle as air will be forced into the steering gear. (5) Completely open valve on Power Steering Analyzer. STEERING RS 19 - 3 STEERING (Continued) (6) Start engine and let idle just long enough to circulate power steering fluid through the analyzer and hoses. Shut off engine. (7) Check power steering fluid level and add fluid as necessary. Start engine again and let idle until the air is out of the fluid. (8) Gauge should read below 300 psi (2068 kPa). If above, inspect the hoses for restrictions and repair as necessary. The initial pressure should be in the range of 100-275 psi (689-1896 kPa) depending on fluid temperature. The flow meter should read above 1.5 GPM. CAUTION: The following test procedure involves testing maximum pump pressure output and flow control valve operation. Do not leave valve closed for more than four seconds as the pump could be damaged. NOTE: Power steering pump maximum pressure for 2.4L engines is 1,200 – 1,350 psi (8,274 – 9,308 kPa). Power steering pump maximum pressure for all other engines is 1,400 – 1,500 psi (9,653 – 10,342 kPa). (9) Close analyzer valve fully three times and record highest pressure indicated each time. All three readings must be within specifications. If any of the three power steering pump pressures are above or below specifications, replace pump. (Refer to 19 STEERING/PUMP - REMOVAL) CAUTION: Do not force the steering to operate against the stops for more than 4 seconds at a time because pump damage can result. (10) Once the pump has been verified as working correctly, completely open the valve on the Power Steering Analyzer. Turn the steering wheel to the extreme left until the stop in the steering gear is met. Hold it there for 2–4 seconds, then release it. Now turn the steering wheel to the right until the right stop is met. Hold it there for 2–4 seconds, then release it. Record the stabilized pressure at each position. Compare the recorded readings to the specifications. If the output pressures are not within 100 psi (689 kPa) of one another against either stop or are below specifications, the steering gear is leaking internally and must be replaced. (Refer to 19 STEERING/GEAR - REMOVAL) DIAGNOSIS AND TESTING - STEERING SYSTEM DIAGNOSIS CHARTS NOTE: There are three diagnosis charts following that cover POWER STEERING NOISE, STEERING WHEEL FEEL, and POWER STEERING FLUID. POWER STEERING NOISE CONDITION OBJECTIONABLE HISS OR WHISTLE* RATTLE OR EXCESSIVE CLUNK** POSSIBLE CAUSES CORRECTION 1. Damaged or mispositioned steering column shaft/coupling dash panel seal. 1. Reposition or replace steering column shaft/coupling dash panel seal. 2. Noisy valve in power steering gear. 2. Replace power steering gear. 3. Mis-routed power steering hose. 3. Check routing of power steering hoses. Ensure hoses do not come in unwanted contact with other components and objects. 1. Power steering gear loose on front suspension crossmember. 1. Inspect power steering gear mounting bolts. Replace as necessary. Tighten to the specified torque. 2. Front suspension crossmember mounting fasteners loose at frame. 2. Tighten the front suspension crossmember mounting fasteners to the specified torque. 3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for wear. Replace worn/loose parts as required. 19 - 4 STEERING RS STEERING (Continued) CONDITION POPPING NOISE CHIRP OR SQUEAL (POWER STEERING PUMP) WHINE, GROWL, MOAN OR GROAN (POWER STEERING PUMP)*** SUCKING AIR SOUND POSSIBLE CAUSES CORRECTION 4. Loose lower control arm mounting bolts at front suspension crossmember. 4. Tighten control arm mounting bolts to the specified torques. 5. Lower control arm pivot bushing worn. 5. Replace lower control arm pivot bushing. 6. Loose strut assembly mounting fasteners at tower or knuckle. 6. Tighten strut assembly fasteners to the specified torque. 7. Power steering fluid hose touching the body of the vehicle. 7. Adjust hose to proper position by loosening, repositioning, and tightening attachments to specified torque. Do not bend tubing. 8. Internal power steering gear noise. 8. Replace power steering gear. 9. Damaged front suspension crossmember. 9. Replace front suspension crossmember. 10. Stabilizer bar link ball joints worn. 10. Replace stabilizer bar link. 11. Lug nuts loose. 11. Tighten lug nuts to specifications. 12. Excessive Wheel bearing free-play. 12. Verify correct driveshaft hub nut torque. Replace bearing if torque is okay. 1. Worn outer tie rod. 1. Check ball joint for free-play; Replace outer tie rod. 2. Loose inner tie rod. 2. Replace power steering gear. 1. Loose power steering pump drive belt. 1. Check and adjust power steering pump drive belt to specifications or replace automatic tensioner where applicable. Replace belt if worn or glazed. 2. Malfuctioning belt auto-tensioner 2. Replace belt auto-tensioner. 1. Low fluid level. 1. Fill power steering fluid reservoir to proper level and check for leaks (make sure all air is bled from the system fluid). 2. Power steering hose touching vehicle body or frame. 2. Adjust hose to proper position by loosening, repositioning, and tightening fitting to specified torque. Do not bend tubing. Replace hose if damaged. 3. Extreme wear of power steering pump internal components. 3. Replace power steering pump and flush system as necessary. 4. Extremely low ambient temperature. 4. Some noise can be expected, but will go away as vehicle warms. Replace pump if noise is excessive. 1. Loose clamp on power steering fluid return hose. 1. Tighten or replace hose clamp. 2. Missing O-Ring on power steering hose connection. 2. Inspect connection and replace O-Ring as required. STEERING RS 19 - 5 STEERING (Continued) CONDITION SQUEAK OR RUBBING SOUND SCRUBBING OR KNOCKING NOISE. POSSIBLE CAUSES CORRECTION 3. Low power steering fluid level. 3. Fill power steering fluid reservoir to proper level and check for leaks. 4. Loose clamp on fluid supply hose. 4. Tighten or replace hose clamp. 1. Steering column shroud rubbing. 1. Realign shrouds as necessary. 2. Steering column shaft rubbing. 2. Move or realign item rubbing shaft. 3. Clockspring noisy. 3. Remove clockspring. Reinstall wheel. If noise is gone, replace clockspring. 4. Seal lubrication inadequate. 4. Lube seal (if external). 5. Steering gear internally noisy. 5. Replace steering gear (if no other cause can be found). 1. Incorrect tire or wheel size. 1. Replace incorrect size tire or wheel with size used as original equipment. 2. Interference between steering gear and other vehicle components. 2. Check for bent or misaligned components and correct as necessary. 3. Steering gear internal stops worn excessively allowing tires to be steered excessively far. 3. Replace steering gear. NOTE: * There is some noise in all power steering systems. One of the most common is a hissing sound evident when turning the steering wheel when at a standstill or when parking and the steering wheel is at the end of its travel. Hiss is a very high frequency noise similar to that experienced while slowly closing a water tap. The noise is present in every valve and results when high velocity fluid passes valve orifice edges. There is no relationship between this noise and the performance of the steering system. This results from internal steering gear rack movement at the bushings and in no way affects the performance of the steering system. This movement may be felt in the steering components during steering wheel reversal. NOTE: *** Power steering pump growl/moan/groan results from the development of high pressure fluid flow. Normally this noise level should not be high enough to be objectionable. NOTE: ** A light clunk may be felt or heard during steering wheel reversal while vehicle is stationary. STEERING WHEEL FEEL CONDITION STEERING WHEEL/ COLUMN CLICKING, CLUNKING OR RATTLING. STEERING WHEEL HAS FORE AND AFT LOOSENESS. POSSIBLE CAUSES CORRECTION 1. Loose steering coupling pinch bolt. 1. Replace pinch bolt and torque to specifications. 2. Steering column bearings. 2. Replace steering column. 3. Excessive intermediate shaft coupling free-play. 3. Replace intermediate shaft. 1. Steering wheel retaining nut not properly tightened and torqued. 1. Tighten the steering wheel retaining nut to its specified torque. 19 - 6 STEERING RS STEERING (Continued) CONDITION STEERING WHEEL, DASH OR VEHICLE VIBRATES DURING LOW SPEED OR STANDSTILL STEERING MANEUVERS. STEERING CATCHES, SURGES OR STICKS IN CERTAIN POSITIONS OR IS DIFFICULT TO TURN. *** POSSIBLE CAUSES CORRECTION 2. Steering column lower bearing spring retainer slipped on steering column shaft. 2. Replace steering column. 3. Loose steering column to instrument panel fasteners. 3. Tighten fasteners to specified torque. 1. Air in the fluid of the power steering system. 1. Bleed air from system following the power steering pump initial operation service procedure.* 2. Tires not properly inflated. 2. Inflate tires to the specified pressure. 3. Excessive engine vibration. 3. Ensure that the engine is tuned properly. 4. Loose tie rod end jam nut. 4. Tighten the inner to outer tie rod jam nut to the specified torque. 5.Overcharged air conditioning system. 5.Check air conditioning pump head pressure and correct as necessary. 6. Grounded engine mount. 6. Repair as necessary. 7. Loose outer tie rod. 7. Replace outer tie rod. 1. Low power steering fluid level. 1. Fill power steering fluid reservoir to specified level and check for leaks. 2. Tires not inflated to specified pressure. 2. Inflate tires to the specified pressure. 3. Lack of lubrication in front lower control arm ball joints. 3. Lubricate ball joints if ball joints are not a lubricated-for-life type ball joint. If ball joint is a lubricated-for-life ball joint, replace ball joint. 4. Worn or binding lower control arm ball joint. 4. Replace lower control arm ball joint. 5. Lack of lubrication in steering gear outer tie rod ends. 5. Lubricate tie rod ends if they are not a lubricated-for-life type. If tie rod end is a lubricated-for-life type, replace tie rod end. 6. Loose power steering pump drive belt. 6. Tighten the power steering pump drive belt to specifications or replace automatic tensioner where applicable. If drive belt is worn or glazed, replace belt. 7. Faulty power steering pump (Perform Power Steering Flow and Pressure Test). 7. Replace power steering pump. 8. Faulty power steering gear (Perform Power Steering Flow and Pressure Test). 8. Replace power steering gear. 9. Excessive friction in steering column or intermediate shaft/coupler. 9. Isolate and correct condition. 10. Excessive friction in power steering gear. 10. Replace power steering gear. STEERING RS 19 - 7 STEERING (Continued) CONDITION STEERING WHEEL DOES NOT RETURN TO CENTER POSITION. EXCESSIVE STEERING WHEEL KICKBACK OR TOO MUCH STEERING WHEEL FREE PLAY. POSSIBLE CAUSES CORRECTION 11. Worn or binding seat and bearing in front strut assembly. 11. Replace seat and bearing in front strut assembly. 1. Tires not inflated properly. 1. Inflate tires to specified pressure. 2. Improper front wheel alignment. 2. Check and adjust wheel alignment as necessary. 3. Lack of lubrication causing binding in front lower control arm ball joints. 3. Lubricate ball joints if ball joints are not a lubricated for life type of ball joint, then inspect ball joint for wear, replace lower control arm as necessary. If ball joint is a lubricated for life ball joint, replace lower control arm ball joint. 4. Steering column coupling joints misaligned. 4. Realign steering column coupling joints. 5. Steering wheel rubbing.** 5. Adjust steering column shrouds to eliminate rubbing condition. 6. Damaged, mispositioned or unlubricated steering column coupler to dash seal.** 6. Replace, reposition, or lubricate dash seal. 7. Binding mount bearing in front strut assembly. 7. Replace mount bearing in front strut assembly. 8. Binding shaft bearing in steering column. 8. Replace the steering column. 9. Excessive friction in steering column coupling. 9. Replace steering column coupling. 10. Excessive friction in power steering gear. 10. Replace power steering gear. 1. Air in the fluid of the power steering system. 1. Bleed air from system following the the power steering pump initial operation service procedure.* 2. Power steering gear loose on cradle/crossmember. 2. Inspect power steering gear mounting bolts. Replace as necessary. Tighten to the specified torque. 3. Steering column coupling or intermediate shaft worn, broken or loose. 3. Replace steering column coupling or intermediate shaft. 4. Free play in steering column. 4. Check all components of the steering column and repair or replace as required. 5. Worn lower control arm ball joints. 5. Replace lower control arm ball joints as required. 6. Loose steering knuckle-to-ball joint stud pinch bolt. 6. Inspect pinch bolt, replace as necessary, and tighten to specified torque. 7. Front wheel bearing loose or worn. 7. Replace hub and bearing as necessary. 8. Loose outer tie rod end. 8. Replace outer tie rod end that has excessive free play. 19 - 8 STEERING RS STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 9. Loose inner tie rod. 9. Replace power steering gear. 10. Defective steering gear rotary valve. 10. Replace power steering gear. NOTE: * Steering shudder can be expected in new vehicles and vehicles with recent steering system repairs. Shudder should dissipate after the vehicle has been driven several weeks. NOTE: ** To evaluate this condition, it may be necessary to disconnect the coupling at the base of the steering column. Turn the steering wheel and feel or listen for internal rubbing in steering column. To avoid damaging the column clockspring, note the following. Before disconnecting coupling, place tires in the straight-ahead position and center steering wheel. Once disconnected, DO NOT rotate steering wheel more than one revolution in either direction and place steering wheel in original location before reconnecting coupling. If this position is lost, the steering column clockspring must be recentered following the procedure found within the procedure for steering column installation in the steering column section. NOTE: *** Increased low speed or stationary steering effort can be expected if the steering fluid is at a high temperature. High fluid temperature usually results from high engine rpm due to trailer towing, ascending grades, or racing the engine for prolonged periods of time. POWER STEERING FLUID CONDITION LOW FLUID LEVEL WITH VISIBLE LEAK. AERATED FLUID.* RESERVOIR FLUID OVERFLOW AND FLUID THAT IS MILKY IN COLOR POSSIBLE CAUSES CORRECTION 1. Loose power steering hose fittings. 1. Tighten the fitting to its specified torque. 2. Damaged or missing fitting seal, gasket, or O-ring. 2. Replace as necessary. 3. Power steering component leaking. 3. Repair or replace the leaking component as required. 1. Low fluid level. 1. Fill power steering fluid reservoir to proper level. 2. Air leak at supply hose, power steering fluid reservoir or pump. 2. Inspect for proper sealing. Repair as necessary. 3. Cracked power steering pump housing. 3. Replace the power steering pump. 1. Water contamination of power steering fluid. 1. Drain the power steering fluid from the system. Flush the system with fresh clean power steering fluid, drain, then refill to the proper level. NOTE: * Extremely cold temperatures may cause power steering fluid aeration. Aeration should subside as fluid warms. STEERING RS 19 - 9 STEERING (Continued) SPECIFICATIONS SPECIAL TOOLS POWER STEERING FASTENER TORQUE POWER STEERING DESCRIPTION TORQUE Power Steering Pump: Flow Control Valve Pressure Fitting 75 N·m (55 ft. lbs.) Mounting Bolts 54 N·m (40 ft. lbs.) Rear Bracket To Engine Mounting Bolts 54 N·m (40 ft. lbs.) Power Steering Analyzer 6815 Steering Gear: Mounting Bolt - Size-M14 183 N·m (135 ft. lbs.) Mounting Bolts Size-M12 95 N·m (70 ft. lbs.) Tie Rod Steering Knuckle Nut 75 N·m (55 ft. lbs.) Tie Rod Jam Nut 75 N·m (55 ft. lbs.) Coupling Pinch Bolt 28 N·m (250 in. lbs.) Power Steering Fluid Hoses: Adapters, Power Steering Analyzer 6893 Hose Tube Nuts 31 N·m (275 in. lbs.) Routing Bracket Bolts 23 N·m (200 in. lbs.) HOSE, POWER STEERING ANALYZER 6959 19 - 10 COLUMN RS COLUMN TABLE OF CONTENTS page COLUMN DESCRIPTION - STEERING COLUMN WARNING WARNINGS AND CAUTIONS . . . . . . DIAGNOSIS AND TESTING - STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . SPECIFICATIONS COLUMN TORQUE . . . . . . . . . . . . . IGNITION SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . LOCK CYLINDER HOUSING DESCRIPTION - IGNITION INTERLOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . 10 . . . . . . . 12 . . . . . . . 12 . . . . . . . 13 . . . . . . . 14 . . . . . . . 15 . . . . . . . 16 . . . . . . 17 . . . . . . . 17 page INSTALLATION . . . KEY/LOCK CYLINDER DESCRIPTION . . . OPERATION . . . . . REMOVAL . . . . . . . INSTALLATION . . . GEAR SHIFT LEVER REMOVAL . . . . . . . INSTALLATION . . . SHROUD REMOVAL . . . . . . . INSTALLATION . . . STEERING WHEEL REMOVAL . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING Fig. 1 Steering Column (Refer to 8 - ELECTRICAL/RESTRAINTS - WARNING) WARNING: BEFORE BEGINNING ANY SERVICE PROCEDURES THAT INVOLVES REMOVING THE AIR BAG. REMOVE AND ISOLATE THE NEGATIVE (-) BATTERY CABLE (GROUND) FROM THE VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR BAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. STEERING COLUMN B.T.S.I. TILT RELEASE LEVER KEY CYLINDER SHIFT LEVER MOUNTING HOLES COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . 21 . 21 . 22 . 22 . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . . . . . . 25 The steering column has been designed to be serviced as a complete assembly (Fig. 1), except for the components listed here. They are the key cylinder, ignition switch, lock cylinder housing, multi-function switch, clockspring, halo lamp, speed control switches, driver airbag, trim shrouds, steering wheel and steering column intermediate shaft (Fig. 2). These replaceable components of the steering column can be serviced without requiring removal of the steering column from the vehicle. - . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . . . . . . 23 DESCRIPTION - STEERING COLUMN 1 2 3 4 5 6 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . . 22 COLUMN WARNINGS AND CAUTIONS . . . . COLUMN RS COLUMN (Continued) Fig. 2 Steering Column And Components (Typical) 19 - 11 19 - 12 COLUMN RS COLUMN (Continued) 1 - CLOCKSPRING WIRING 2 - STEERING WHEEL 3 - UPPER SHROUD 4 - FIXED SHROUD 5 - SCREW 6 - STEERING COLUMN MOUNTING PLATE 7 - NUT 8 - DASH PANEL STEERING COLUMN MOUNTING BRACKET 9 - STUDS (4) 10 - STEERING COLUMN LOCKING PIN 11 - NUT/WASHER ASSEMBLY 12 - STEERING COLUMN ASSEMBLY 13 - LOWER SHROUD 14 - SCREWS 15 - STEERING WHEEL RETAINING NUT WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIR BAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIR BAG COMPONENTS, HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIR BAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS. WARNING: SAFETY GOGGLES SHOULD BE WORN AT ALL TIMES WHEN WORKING ON STEERING COLUMNS. CAUTION: Disconnect negative (ground) cable from the battery before servicing any column component. CAUTION: Do not attempt to remove the pivot pins to disassemble the tilting mechanism. Damage will occur. DIAGNOSIS AND TESTING - STEERING COLUMN For diagnosis of conditions relating to the steering column (Refer to 19 - STEERING - DIAGNOSIS AND 16 17 18 19 20 21 22 23 24 25 26 27 28 29 - STEERING WHEEL DAMPER CLOCKSPRING SCREW MULTI-FUNCTION SWITCH PINCH BOLT STEERING COLUMN COUPLER PINCH BOLT RETAINING PIN DASH PANEL SILENCER SHELL INTERMEDIATE SHAFT SHIELD AND SEAL INTERMEDIATE SHAFT ROLL PIN POWER STEERING GEAR FRONT SUSPENSION CRADLE/CROSSMEMBER TESTING) and (Refer to 19 - STEERING - DIAGNOSIS AND TESTING). REMOVAL NOTE: Before proceeding, (Refer to 19 - STEERING/ COLUMN - WARNING). (1) Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before beginning the column removal procedure. (2) Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. (3) Remove the lower shroud (Refer to 19 STEERING/COLUMN/LOWER SHROUD - REMOVAL). (4) Remove the traction off switch. (5) Remove the upper shroud. (6) Remove the cluster trim bezel (Refer to 23 BODY/INSTRUMENT PANEL/CLUSTER BEZEL REMOVAL). (7) Remove the knee blocker (Refer to 23 - BODY/ INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - REMOVAL). (8) Remove the parking brake handle link. (9) Remove the knee blocker reinforcement (Refer to 23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER - REMOVAL). (10) Remove the airbag (Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - REMOVAL). (11) Remove the steering wheel retaining nut. (12) Remove the vibration damper weight. (13) Remove the steering wheel (Refer to 19 STEERING/COLUMN/STEERING WHEEL REMOVAL). (Fig. 3) (14) Disconnect the wiring harness connectors from the clockspring, multi-function switch, halo lamp, SKIM module, ignition switch and BTSI solenoid. COLUMN RS 19 - 13 COLUMN (Continued) Fig. 3 STEERING WHEEL REMOVAL 1 - STEERING WHEEL 2 - PULLER Fig. 5 PINCH BOLT 1 - PINCH BOLT 2 - STEERING COLUMN (15) Disconnect the shift cable at the lever. (Fig. 4) Fig. 6 CLOCKSPRING Fig. 4 SHIFT CABLE MOUNTING 1 - SHIFT CABLE MOUNT 2 - SHIFT LEVER (16) Remove the pinch side clip, then remove the cable from the bracket on the column. (17) Remove the pinch bolt coupling. (Fig. 5) (18) Loosen the two lower mounting nuts. (19) Remove the two upper mounting nuts (20) Remove the steering column. (21) Remove the clockspring (Refer to 8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING - REMOVAL). (Fig. 6) (22) Remove the mounting plate with the multifunction switch. (23) Remove the halo-lamp. (24) Remove the ignition key cylinder (Refer to 19 - STEERING/COLUMN/KEY/LOCK CYLINDER REMOVAL). (25) Remove the BTSI. INSTALLATION To service the steering wheel components or the airbag (Refer to 8 - ELECTRICAL/RESTRAINTS/ DRIVER AIRBAG - REMOVAL). Follow all WARNINGS AND CAUTIONS. (1) Make sure the front wheels of the vehicle are still in the STRAIGHT AHEAD position before beginning the column installation procedure. (2) Install the BTSI. (3) Install the ignition key cylinder (Refer to 19 STEERING/COLUMN/KEY/LOCK CYLINDER INSTALLATION). (4) Install the halo-lamp. 19 - 14 COLUMN RS COLUMN (Continued) (5) Install the mounting plate with the multi-function switch. (6) Install the clockspring (Refer to 8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING - INSTALLATION). (7) Install the steering column to the vehicle. (8) Install the two upper mounting nuts (9) Tighten the two lower mounting nuts and the two upper mounting nuts. Tighten to 12 N·m (105 in. lbs.). (10) Install the coupling onto the intermediate shaft and install the pinch bolt. Tighten the pinch bolt to 28 N·m (250 in. lbs.). (11) Install the cable from the bracket on the column, then install the pinch side clips. (12) Reconnect the shift cable at the lever. (13) Reconnect the wiring harness connectors to the clockspring, multi-function switch, halo lamp, SKIM module, ignition switch and BTSI solenoid. (14) Install the steering wheel (Refer to 19 STEERING/COLUMN/STEERING WHEEL INSTALLATION). (15) Install the vibration damper weight. (16) Install the steering wheel retaining nut. Tighten the nut to 61 N·m (45 ft. lbs.) (17) Install the airbag (Refer to 8 - ELECTRICAL/ RESTRAINTS/DRIVER AIRBAG - INSTALLATION). (18) Install the knee blocker reinforcement (Refer to 23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER - INSTALLATION). (19) Install the parking brake handle link. (20) Install the knee blocker (Refer to 23 - BODY/ INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION). (21) Install the cluster trim bezel (Refer to 23 BODY/INSTRUMENT PANEL/CLUSTER BEZEL INSTALLATION). (22) Install the upper shroud (Refer to 19 STEERING/COLUMN/LOWER SHROUD - INSTALLATION). (23) Install the traction off switch. (24) Install the lower shroud. SPECIFICATIONS COLUMN TORQUE N·m Ft. Lbs. In. Lbs. Steering Wheel Retaining Nut 61 45 — Steering Column Mounting Bracket Attaching Nuts 12 — 105 Steering Column Coupling Pinch Bolt 28 — 250 Steering Column Airbag Module Attaching Nuts 11 — 100 DESCRIPTION COLUMN RS IGNITION SWITCH 19 - 15 (3) Remove parking brake release cable from handle (Fig. 9). REMOVAL The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder (Fig. 7). For ignition switch terminal and circuit identification, 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. Fig. 9 Parking Brake Release Cable 1 - PARKING BRAKE CABLE 2 - PARKING BRAKE HANDLE (4) Remove screws holding steering shrouds (Fig. 10)and remove lower shroud. column Fig. 7 Ignition Switch—Viewed From Below Column 1 - IGNITION SWITCH 2 - LOCK CYLINDER HOUSING 3 - RETAINING TABS (1) Disconnect negative cable from battery. (2) Remove steering column cover retaining screws (Fig. 8). Fig. 10 Steering Column Shroud Screws 1 - STEERING WHEEL 2 - SCREWS 3 - LOWER STEERING COLUMN SHROUD Fig. 8 Steering Column Cover 1 - SCREWS 2 - STEERING COLUMN COVER 19 - 16 COLUMN RS IGNITION SWITCH (Continued) (5) Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder (Fig. 11). Fig. 13 Ignition Switch Retaining Tab 1 - IGNITION SWITCH 2 - RETAINING TAB Fig. 11 Lock Cylinder Retaining Tab 1 - IGNITION SWITCH 2 - RETAINING TAB (6) Remove ignition switch mounting screw (Fig. 12) with a #10 Torxt tamper proof bit. Fig. 14 Removing Ignition Switch 1 - IGNITION SWITCH 2 - RETAINING TAB INSTALLATION Fig. 12 Ignition Switch Mounting Screw 1 - MOUNTING SCREW 2 - IGNITION SWITCH (7) Depress retaining tab (Fig. 8) or (Fig. 13) and gently pry ignition switch from steering column (Fig. 14). (8) Disconnect electrical connectors from ignition switch and remove switch (Fig. 15). The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder (Fig. 7) . For ignition switch terminal and circuit identification, refer to the Wiring Diagrams section. (1) Ensure the ignition switch is in the RUN position and the actuator shaft in the lock housing is in the RUN position. (2) Install electrical connectors to ignition switch. COLUMN RS 19 - 17 IGNITION SWITCH (Continued) (7) Check for proper operation of ignition switch and key-in warning switch. LOCK CYLINDER HOUSING DESCRIPTION - IGNITION INTERLOCK All vehicles equipped with automatic transaxles have an interlock system. The system prevents shifting the vehicle out of Park unless the ignition lock cylinder is in the Unlock, Run or Start position. In addition, the operator cannot rotate the key to the lock position unless the shifter is in the park position. On vehicles equipped with floor shift refer to the - Transaxle for Automatic Transmission Shifter/ Ignition Interlock. REMOVAL Fig. 15 Ignition Switch Connectors 1 - KEY IN SWITCH 2 - PRNDL SWITCH 3 - IGNITION SWITCH (1) Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. (2) Remove the screws attaching the lower steering column cover to the instrument panel (Fig. 17), then remove the cover from the lower instrument panel. (3) Carefully install the ignition switch. The switch will snap over the retaining tabs (Fig. 16) . Install mounting screw (Fig. 12). (4) Install upper and lower shrouds. (5) Install key cylinder (cylinder retaining tab will depress only in the RUN position). (6) Connect negative cable to battery. Fig. 17 Lower Steering Column Cover Attachment 1 2 3 4 5 6 7 Fig. 16 Ignition Switch Installation 1 - IGNITION SWITCH 2 - ACTUATOR SHAFT 3 - RETAINING TABS - PARK BRAKE RELEASE HANDLE - STEERING COLUMN COVER - STEERING COLUMN - ATTACHING CLIP - ATTACHING SCREWS - HOOD RELEASE LEVER - ATTACHING SCREWS 19 - 18 COLUMN RS LOCK CYLINDER HOUSING (Continued) (3) Remove the parking brake release cable from the parking brake release lever (Fig. 18), then move the lower steering column cover out of the way. Fig. 18 Parking Brake Release Cable Attachment To Release Lever 1 - PARK BRAKE PEDAL RELEASE CABLE 2 - PARK BRAKE RELEASE LEVER 3 - LOWER STEERING COLUMN COVER (4) Remove the 10 bolts attaching the lower steering column cover liner to the instrument panel (Fig. 19), then remove the lower steering column cover liner. Fig. 20 Steering Column Shroud Screws 1 - STEERING WHEEL 2 - SCREWS 3 - LOWER STEERING COLUMN SHROUD (6) Remove the trim bezel on the instrument panel above the steering column. The trim bezel is mounted to the instrument panel using 2 screws (one on each side of the column) and retaining clips. (7) Remove the 2 screws securing the steering column fixed shroud to the steering column (Fig. 21), then remove the shroud. Fig. 19 Liner Attachment 1 2 3 4 5 6 - STEERING COLUMN COVER LINER - ATTACHING BOLTS - ATTACHING BOLTS - STEERING COLUMN - ATTACHING BOLTS - ATTACHING BOLTS (5) Remove the 3 screws attaching the upper and lower shrouds to the steering column (Fig. 20), then separate and remove both shrouds. Fig. 21 Fixed Shroud Mounting 1 - SCREWS 2 - SHROUD COLUMN RS 19 - 19 LOCK CYLINDER HOUSING (Continued) (8) Remove the two screws holding the metal cover in place below the shifter/ignition interlock linkage (Fig. 22), then remove the cover. • Depress and hold the retaining tab on the bottom of the lock cylinder housing (Fig. 24). • Pull the key cylinder straight out of the lock cylinder housing. Fig. 22 Cover Removal/Installation 1 - IGNITION SWITCH 2 - SCREW 3 - COVER Fig. 24 Cylinder Retaining Tab 1 - IGNITION SWITCH 2 - RETAINING TAB (9) Disconnect the shifter/ignition interlock link from the lever on the lock cylinder housing (Fig. 23). (11) Remove the vehicle wiring harness connector from the key cylinder halo lamp (Fig. 25). Fig. 23 Shifter/Ignition Interlock Linkage Disconnected Fig. 25 Wiring Harness Connection To Halo Lamp 1 - LEVER 2 - LINK 3 - LOCK CYLINDER HOUSING (10) Remove the key cylinder. To do this: • Turn the key placing the key cylinder in the ON position. 1 2 3 4 - IGNITION SWITCH STEERING COLUMN ASSEMBLY WIRING HARNESS CONNECTOR IGNITION SWITCH HALO LIGHT (12) Remove the key cylinder halo lamp from the lock cylinder housing. 19 - 20 COLUMN RS LOCK CYLINDER HOUSING (Continued) (13) Remove the ignition switch mounting screw (Fig. 26). Fig. 28 Tilt Mechanism Spring Removal/Installation Fig. 26 Ignition Switch Mounting Screw 1 - MOUNTING SCREW 2 - IGNITION SWITCH 1 - SPRINGS 2 - POST 3 - GROOVE (14) Depress the two retaining tabs (Fig. 27), then remove the ignition switch from the lock cylinder housing. Fig. 29 Lock Cylinder Housing Mounting Screw Location 1 - SPRINGS 2 - MOUNTING SCREWS Fig. 27 Ignition Switch Retaining Tabs 1 - IGNITION SWITCH 2 - LOCK CYLINDER HOUSING 3 - RETAINING TABS (15) Disconnect both tilt mechanism springs from their mounting posts on the tilt housing (Fig. 28), then move them to the side out of the way (Fig. 29). (16) While supporting the lock cylinder housing, remove both mounting screws securing the lock cylinder housing to the column (Fig. 29). (17) Remove the lock cylinder housing from the bottom of the steering column. INSTALLATION (1) Install the lock cylinder housing in the bottom of the steering column lining up the mounting holes. (2) Install the self-tapping lock cylinder housing mounting screws through the top of the column into the housing (Fig. 29) . Tighten the two mounting screws to a torque of 11 N·m (100 in. lbs.). (3) Connect both tilt mechanism springs back onto their mounting posts making sure the spring hooks engage the grooves in the posts (Fig. 28) . (4) Ensure that the ignition switch and the actuator shaft in the lock cylinder housing are in the ON position. COLUMN RS 19 - 21 LOCK CYLINDER HOUSING (Continued) (5) Carefully install the ignition switch over the actuator shaft (Fig. 30) . The switch will snap over the retaining tabs on the housing. Fig. 30 Ignition Switch Installation 1 - IGNITION SWITCH 2 - ACTUATOR SHAFT 3 - RETAINING TABS (6) Install the ignition switch mounting screw (Fig. 26) . (7) Install the key cylinder halo lamp on the lock cylinder housing. (8) Install the vehicle wiring harness connector onto the key cylinder halo lamp (Fig. 25) . (9) Install the key cylinder (with key in it turned to the ON position) by sliding it straight into the lock cylinder housing aligning the retaining tab on the key cylinder with the hole in the lock cylinder housing. (10) Turn the key to the OFF position and remove the key. (11) Connect the shifter/ignition interlock link to the lever on the lock cylinder housing by aligning the retaining tab on the lever with the ramp on the link (Fig. 23) , then pushing the two together. (12) Install the metal cover in place below the shifter/ignition interlock linkage using the two screws (Fig. 22) . (13) Install the steering column fixed shroud on the steering column (Fig. 21) using its 2 mounting screws. (14) Install the trim bezel on the instrument panel above the steering column. The trim bezel is mounted to the instrument panel using 2 screws (one on each side of the column) and retaining clips. (15) Install the lower steering column shroud on the steering column. Install and securely tighten the center screw attaching the lower shroud to the tilt head on the column (Fig. 20) . (16) Install the upper steering column shroud over the tilt head of the steering column snapping it into place on the lower shroud. Install and securely tighten the 2 remaining screws attaching the upper shroud to the lower shroud (Fig. 20) . (17) Install the steering column cover liner on the instrument panel below the steering column (Fig. 19) . Install and securely tighten the 10 bolts attaching the steering column cover liner to the instrument panel. (18) Install the parking brake pedal release cable on the parking brake release lever in the lower steering column cover (Fig. 18) . (19) Install the lower steering column trim cover on the instrument panel below the steering column. Install and securely the screws attaching the lower steering column cover to the instrument panel (Fig. 17) . (20) Connect the negative (ground) cable on the battery terminal. KEY/LOCK CYLINDER DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION The ignition key rotates the cylinder to 5 different detents (Fig. 31) : • Accessory • Off (lock) • Unlock • On/Run • Start Fig. 31 Ignition Lock Cylinder Detents 19 - 22 COLUMN RS KEY/LOCK CYLINDER (Continued) REMOVAL (1) Disconnect negative cable from battery. (2) Remove steering column cover retaining screws. (3) Remove screws holding steering column shrouds and remove lower shroud. (4) Place key cylinder in RUN position. Depress lock cylinder retaining tab on the bottom of the lock housing and remove key cylinder. INSTALLATION (1) Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). (2) The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig. 32) . (2) Remove the knee blocker reinforcement (Refer to 23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER - REMOVAL). (3) Remove the upper and lower shrouds (Refer to 19 - STEERING/COLUMN/LOWER SHROUD REMOVAL). (4) Remove the cluster trim bezel (Refer to 23 BODY/INSTRUMENT PANEL/CLUSTER BEZEL REMOVAL). (5) Remove the fixed shroud from the column. (6) Disconnect the electrical connector to the BTSI. (7) Remove the two screws securing the BTSI to the steering column. (Fig. 33) Fig. 33 SHIFT LEVER / B.T.S.I 1 - B.T.S.I. 2 - SHIFT LEVER Fig. 32 Socket in Lock Cylinder Housing 1 - LOCK CYLINDER HOUSING 2 - SOCKET (3) Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. (4) Turn the key to the Off position. Remove the key. (5) Install lower steering column shroud. (6) Install steering column cover. (7) Connect negative cable to battery. GEAR SHIFT LEVER REMOVAL (1) Remove the knee blocker (Refer to 23 - BODY/ INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - REMOVAL). (8) Disconnect the SKIM electrical wire connector. (9) Remove the SKIM from the steering column. (10) Disconnect the autostick wiring connector (if equipped with autostick). (11) Disconnect the shifter cable at the shifter. (12) Remove the three screws securing the shifter to the steering column. (Fig. 34) (13) Remove the shift lever from the column. INSTALLATION (1) Install the shifter cable to the shifter. (2) Install the three screws securing the shifter to the steering column. (3) Install the shifter cable at the handle. (4) Install the SKIM to the steering column. (5) Reconnect the SKIM electrical wire connector. (6) Reconnect the autostick wiring connector (if equipped with autostick). (7) Install the two screws securing the BTSI to the steering column. (8) Reconnect the electrical connector to the BTSI. (9) Install the fixed shroud to the column. COLUMN RS 19 - 23 GEAR SHIFT LEVER (Continued) Fig. 34 SHIFT LEVER (10) Install the cluster trim bezel (Refer to 23 BODY/INSTRUMENT PANEL/CLUSTER BEZEL INSTALLATION). (11) Install the upper and lower shrouds (Refer to 19 - STEERING/COLUMN/LOWER SHROUD INSTALLATION). (12) Install the knee blocker reinforcement (Refer to 23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER - INSTALLATION). (13) Install the knee blocker (Refer to 23 - BODY/ INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION). Fig. 35 UPPER AND LOWER SHROUDS 1 2 3 4 5 - FIXED SHROUD UPPER SHROUD CLOCKSPRING LOWER SHROUD STEERING COLUMN (1) Rotate key cylinder to the lock position and remove key. Rotate the steering wheel a half turn to the left until the steering column lock engages keeping the steering column in the locked position (Fig. 36). SHROUD REMOVAL (1) Remove the three screws from the lower shroud. (2) Unsnap and remove the lower shroud. (3) Lift off upper shroud from the steering column. (Fig. 35) INSTALLATION (1) Install the upper shroud in place over the steering column. (2) Snap the lower shroud to the upper shroud. (3) Install and tighten the three retaining screws. Tighten the screws to 11 N·m (100 in. lbs.). (Fig. 35) STEERING WHEEL REMOVAL NOTE: Before proceeding, (Refer to 19 - STEERING/ COLUMN - WARNING). Fig. 36 Steering Wheel In Locked Position 1 - STEERING WHEEL (2) Remove the 3 bolts (one in each spoke of the steering wheel) attaching the airbag module to the steering wheel. Lift the airbag module from the steering wheel. (3) Disconnect wiring connectors from the airbag, horn switch wire, and speed control switches (Fig. 37). Remove the wiring harness routing clip from the airbag module studs. 19 - 24 COLUMN RS STEERING WHEEL (Continued) Fig. 37 Airbag Module Wiring Connections 1 2 3 4 - WIRING HARNESS ROUTING CLIP - AIRBAG MODULE CONNECTOR - HORN SWITCH CONNECTOR - SPEED CONTROL SWITCH CONNECTORS If the steering wheel is equipped with remote radio controls, disconnect the connector from the clockspring. Release the connector by depressing the tang as shown (Fig. 38), then slide the connector apart. Fig. 39 Steering Wheel Retaining Nut 1 2 3 4 5 6 - STEERING COLUMN SHAFT STEERING WHEEL DAMPER STEERING WHEEL RETAINING NUT CLOCKSPRING CLOCKSPRING WIRING HARNESS STEERING WHEEL CAUTION: When installing steering wheel puller bolts in steering wheel, (Fig. 40) do not thread bolt into steering wheel more than a half inch. If bolts are threaded into the steering wheel more than a half inch they will contact and damage the clockspring. (6) Remove the steering wheel from steering column shaft using a steering wheel puller (Fig. 40). Fig. 38 Releasing Remote Radio Control Connector 1 - STEERING WHEEL 2 - REMOTE RADIO CONTROL CONNECTOR (4) Remove the steering wheel retaining nut (Fig. 39) from the steering column shaft. (5) Remove the steering wheel damper (Fig. 39) from the steering wheel. CAUTION: Do not bump or hammer on steering column or steering column shaft when removing steering wheel from steering column shaft. Fig. 40 Removing Steering Wheel From Steering Column Shaft 1 - STEERING WHEEL 2 - CLOCK SPRING WIRING HARNESS RS COLUMN 19 - 25 STEERING WHEEL (Continued) INSTALLATION CAUTION: Do not force steering wheel onto steering column shaft by driving it on. Pull steering wheel down onto shaft using only the steering wheel retaining nut. (1) Align master splines on steering wheel and steering shaft, and flats on steering wheel with formations on clockspring. Install the steering wheel on the steering column shaft. All wiring leads from the clockspring must be routed as shown (Fig. 41). Fig. 41 Steering Wheel And Clock Spring Wire Routing 1 - STEERING WHEEL 2 - CLOCK SPRING 3 - CLOCK SPRING WIRING LEADS NOTE: Before installing the damper on the steering wheel, inspect the damper to ensure the rubber isolator on the damper is not deteriorated or damaged. If the damper is installed with a damaged isolator a buzz, squeak or rattle condition may develop. (2) Install the steering wheel damper on the steering wheel. When damper is installed, it must be positioned on the steering wheel as shown in (Fig. 39). (3) Install the steering wheel retaining nut. Tighten the steering wheel retaining nut to a torque of 61 N·m (45 ft. lbs.). (4) Connect the wiring lead from the clockspring to the remote radio control connector (Fig. 38). (5) Install the wiring leads from the clockspring on the airbag, horn switch wire, and speed control switches (Fig. 37). Attach the wire routing clip to the studs on the airbag module. (6) Install the airbag module in the steering wheel. (7) Install the 3 bolts (1 in each spoke of the steering wheel) attaching the airbag module to the steering wheel. Tighten the 3 airbag module attaching nuts to a torque of 11 N·m (100 in. lbs.). 19 - 26 GEAR RS GEAR TABLE OF CONTENTS page GEAR DESCRIPTION . . . . . . . . . . . OPERATION . . . . . . . . . . . . . WARNING WARNINGS AND CAUTIONS REMOVAL REMOVAL - LHD GEAR . . . REMOVAL - RHD GEAR .. . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . 29 GEAR DESCRIPTION This vehicle is equipped with a rack and pinion power steering gear (Fig. 1). It is mounted to the underside of the front suspension cradle/crossmember. The steering column is attached to the gear through the use of an intermediate shaft and couplers. The outer ends of the power steering gear’s outer tie rods connect to the steering knuckles. NOTE: The power steering gear should NOT be serviced or adjusted unless DaimlerChrysler Corporation authorizes. If a malfunction or oil leak occurs, the complete steering gear should be replaced. Only the outer tie rods may be replaced separately from the rest of the gear. OPERATION Turning of the steering wheel is converted into linear (side-to-side) travel through the meshing of the helical pinion teeth with the rack teeth in the steering gear. This travel pushes and pulls the tie rods to change the direction of the vehicle’s front wheels. Power assist steering provided by the power steering pump is controlled by an open center, rotary type control valve which directs oil from the pump to either side of the integral rack piston upon demand. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. As required steering effort increases, as in a turn, the torsion bar twists, causing relative rotary motion between the rotary valve body and the valve spool. This movement directs oil behind the integral rack piston which, in turn, builds hydraulic pressure and assists in the turning effort. page INSTALLATION INSTALLATION - LHD GEAR INSTALLATION - RHD GEAR SPECIAL TOOLS POWER STEERING GEAR OUTER TIE ROD REMOVAL . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . 34 Manual steering control of the vehicle can be maintained if power steering assist is lost. However, under this condition, steering effort is significantly increased. WARNING WARNINGS AND CAUTIONS WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: When the system is open, cap all open ends of the hoses, power steering pump fittings or power steering gear ports to prevent entry of foreign material into the components. REMOVAL REMOVAL - LHD GEAR (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much fluid as possible from the power steering fluid reservoir. Use care not to damage the filter mesh below the fluid surface. GEAR RS 19 - 27 GEAR (Continued) Fig. 1 Power Steering Gear (Typical) 1 2 3 4 5 6 7 - TIE ROD JAM NUT INNER TIE ROD STEERING GEAR MOUNTING BRACKET POWER STEERING GEAR FLUID LINES STEERING COLUMN INTERMEDIATE SHAFT INNER TIE ROD OUTER TIE ROD 8 - TIE ROD JAM NUT 9 - BOOT/BELLOWS 10 - STEERING GEAR BOOT BREATHER TUBE 11 - BOOT/BELLOWS 12 - OUTER TIE ROD CAUTION: Locking the steering column in the straight-ahead position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler. (3) Position the steering wheel in the STRAIGHTAHEAD position. Lock the steering wheel in place using a steering wheel holding tool. (4) With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler (Fig. 2). (5) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (6) Remove front wheel and tire assemblies. (7) Remove front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - REMOVAL) (8) Remove a single hose at power steering cooler and allow fluid to drain. (9) Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement (Fig. 3). Fig. 2 Steering Column Shaft To Intermediate Shaft Attachment 1 2 3 4 5 - STEERING COLUMN SHAFT COUPLER NUT SAFETY PIN INTERMEDIATE SHAFT PINCH BOLT 19 - 28 GEAR RS GEAR (Continued) EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/LEAK DETECTION PUMP - REMOVAL) (12) Remove both outer tie rods from steering knuckles, using Puller, Special Tool C-3894–A (Fig. 5). Fig. 3 Power Steering Cooler 1 - CRADLE CROSSMEMBER REINFORCEMENT 2 - POWER STEERING COOLER (10) On both sides of vehicle, remove nut attaching outer tie rod end to steering knuckle (Fig. 4). Remove nut by holding tie rod end stud with a socket while loosening and removing nut with wrench. Fig. 5 Tie Rod Removal With Tool C-3894-A 1 - OUTER TIE ROD 2 - SPECIAL TOOL C-3894-A 3 - STEERING KNUCKLE (13) Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of two different thread sizes. Note the location of the various sizes. Fig. 4 Removing/Installing Tie Rod End Attaching Nut 1 2 3 4 5 - TIE ROD END STEERING KNUCKLE WRENCH SOCKET TIE ROD END STUD (11) Remove bolts fastening leak detection pump to cradle crossmember reinforcement. (Refer to 25 - (14) Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle crossmember (Fig. 6). Remove the 2 bolts fastening the reinforcement and rear of cradle crossmember to the body of the vehicle. Remove lower rear bushings, then the reinforcement. (15) If the vehicle is equipped with All-WheelDrive, remove the power transfer unit (Refer to 21 TRANSMISSION/TRANSAXLE/POWER TRANSFER UNIT - REMOVAL). (16) Remove tube nuts and power steering pressure and return hoses from the power steering gear (Fig. 7). GEAR RS 19 - 29 GEAR (Continued) (20) Remove the power steering gear from the vehicle. REMOVAL - RHD GEAR (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much fluid as possible from the power steering fluid reservoir. CAUTION: Locking the steering column in the straight-ahead position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler. Fig. 6 Cradle Crossmember Reinforcement Attachment 1 2 3 4 5 6 7 - STEERING GEAR RIGHT LOWER CONTROL ARM LEFT LOWER CONTROL ARM CRADLE CROSSMEMBER REINFORCEMENT REAR CRADLE CROSSMEMBER ISOLATOR BUSHING STABILIZER BAR CRADLE CROSSMEMBER (17) Remove the 3 bolts and nuts mounting the steering gear to the front suspension cradle (Fig. 8). NOTE: The next step must be done to allow the removal of the steering gear from the front suspension cradle. The steering gear can not be removed from the vehicle with the intermediate coupler attached to the steering gear. (18) Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin (Fig. 9). Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing with the knurled nut (Fig. 9). Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler. (19) Separate the coupler from the shaft of the steering gear. (3) Position the steering wheel in the STRAIGHTAHEAD position. Lock the steering wheel in place using a steering wheel holding tool. (4) With the ignition key in the locked position turn the steering wheel to the left until the steering wheel is in the locked position. (5) With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler (Fig. 2). (6) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (7) Remove front wheel and tire assemblies. (8) If power steering cooler equipped, remove a hose at power steering cooler and allow fluid to drain. (9) Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement (Fig. 3). (10) On both sides of vehicle, remove nut attaching outer tie rod end to steering knuckle (Fig. 4). Remove nut by holding tie rod end stud with a socket while loosening and removing nut with wrench. (11) Remove both tie rod ends from steering knuckles using Puller, Special Tool C-3894–A (Fig. 5). (12) Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of two different thread sizes. Note the location of the various sizes. (13) Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle crossmember (Fig. 6). Remove the 2 bolts fastening the reinforcement and rear of cradle crossmember to the body of the vehicle. Remove the reinforcement. (14) If the vehicle is equipped with All-WheelDrive, remove the power transfer unit (Refer to 21 TRANSMISSION/TRANSAXLE/POWER TRANSFER UNIT - REMOVAL). 19 - 30 GEAR RS GEAR (Continued) Fig. 7 Hoses To Power Steering Gear - 3.3L/3.8L Engine 1 2 3 4 5 6 7 - RETURN HOSE (TO RESERVOIR) PRESSURE HOSE (FROM PUMP) CRADLE CROSSMEMBER PRESSURE HOSE ROUTING CLAMP RETURN HOSE ROUTING CLAMP PRESSURE HOSE TUBE NUT POWER STEERING GEAR (15) Remove the power steering fluid pressure and return hoses from the power steering gear (Fig. 10). (16) Remove the routing clamp bolt securing the power steering fluid hoses to the rear of the cradle crossmember (Fig. 11). Allow the hoses to hang down out of the way. (17) Remove the heat shield from the steering gear (Fig. 10). (18) Remove the 2 bolts and nuts mounting the steering gear to the front suspension cradle. NOTE: The next step must be done to allow the removal of the steering gear from the front suspension cradle. The steering gear cannot be removed from the vehicle with the intermediate coupler attached to the steering gear. 8 - ABS BRACKET 9 - ROUTING CLIP 10 - LEAK DETECTION PUMP FILTER 11 - RETURN HOSE TUBE NUT 12 - ROUTING CLIP (19) Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin (Fig. 9). Install Remover/Installer, Special Tool 6831A, through the center of the roll pin, securing with the knurled nut (Fig. 9). Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler. (20) Separate the coupler from the steering gear shaft. (21) Remove the power steering gear from the vehicle. GEAR RS 19 - 31 GEAR (Continued) Fig. 8 Steering Gear Mounting To Suspension Cradle 1 2 3 4 - POWER STEERING GEAR MOUNTING BOLTS (12 MM) MOUNTING BOLT (14 MM) FRONT SUSPENSION CRADLE CROSSMEMBER Fig. 10 RHD Gear Heat Shield And Hose Fittings 1 2 3 4 5 - HEAT SHIELD CRADLE CROSSMEMBER RETURN HOSE FITTING PRESSURE HOSE FITTING POWER STEERING GEAR Fig. 9 Removing Roll Pin From Intermediate Coupler 1 2 3 4 5 6 7 8 - INTERMEDIATE COUPLER KNURLED NUT SUSPENSION CRADLE REMOVER SPECIAL TOOL 6831A STEERING GEAR NUT ROLL PIN THREADED ROD Fig. 11 RHD Power Steering Gear - 2.5L Diesel Shown 1 2 3 4 5 6 7 - RETURN HOSE PRESSURE HOSE CRADLE CROSSMEMBER POWER STEERING GEAR RETURN HOSE FITTING PRESSURE HOSE FITTING HOSE ROUTING CLAMP 19 - 32 GEAR RS GEAR (Continued) INSTALLATION INSTALLATION - LHD GEAR (1) Install the power steering gear up in the front suspension cradle, leaving room to install intermediate coupler. (2) Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear. (3) Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut (Fig. 12). Hold threaded rod stationary while turning nut, this will pull the roll pin into the intermediate coupler. MISSION/TRANSAXLE/POWER TRANSFER UNIT INSTALLATION). CAUTION: Proper torque on the cradle reinforcement to suspension cradle mounting bolts is very important. (7) Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember (Fig. 6). Tighten the M-14 size bolts to a torque of 153 N·m (113 ft. lbs.). Tighten the M-12 size bolts to a torque of 106 N·m (78 ft. lbs.). (8) Install the lower control arm rear bushing retainer bolts (M-10 size) through reinforcement on each side of each lower control arm rear bushing. Tighten bolts to a torque of 61 N·m (45 ft. lbs.). (9) Install the two bolts and bushings attaching the reinforcement and rear of cradle crossmember to body of vehicle (Fig. 6). Tighten bolts to a torque of 163 N·m (120 ft. lbs.). (10) Install outer tie rod end into steering knuckle. Start outer tie rod to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a socket (Fig. 4), tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket (Fig. 13), tighten the tie rod end attaching nut to a torque of 75 N·m (55 ft. lbs.). Fig. 12 Installing Roll Pin In Intermediate Coupler 1 2 3 4 5 - INTERMEDIATE SHAFT COUPLER SUSPENSION CRADLE CROSSMEMBER KNURLED NUT ROLL PIN POWER STEERING GEAR CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important. (4) Install steering gear on the front suspension cradle. Install the 3 steering gear mounting bolts and nuts (Fig. 8). Tighten the 3 mounting bolts to the following torque values: • 14 mm bolt – 183 N·m (135 ft. lbs.) torque • 12 mm bolt – 95 N·m (70 ft. lbs.) torque (5) Attach the power steering fluid pressure and return hoses to the correct ports on the power steering gear (Fig. 7). Tighten the hose tube nuts at the gear to a torque of 31 N·m (275 in. lbs.). (6) If the vehicle is equipped with All-Wheel-Drive, install the power transfer unit (Refer to 21 - TRANS- Fig. 13 Torquing Tie Rod End Attaching Nut 1 2 3 4 5 - STEERING KNUCKLE TIE ROD END CROWFOOT SOCKET TORQUE WRENCH (11) Install leak detection pump on cradle crossmember reinforcement. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/LEAK DETECTION PUMP - INSTALLATION) RS GEAR 19 - 33 GEAR (Continued) (12) Install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 3). Install the mounting bolts and tighten to 11 N·m (100 in. lbs.). When installing mounting bolts, include pressure hose routing clamp. (13) Reconnect previously disconnected hose at power steering cooler and install clamp. (14) Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to 135 N·m (100 ft. lbs.). (15) Install front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - INSTALLATION) (16) Lower the vehicle to a level where the interior of vehicle is accessible. (17) With the wheels pointed approximately STRAIGHT-AHEAD, align the intermediate shaft with the steering column coupler. Assemble the steering column shaft coupler onto the steering gear intermediate coupler (Fig. 2). Install steering column coupler to intermediate shaft retaining pinch bolt. Tighten the pinch bolt nut to a torque of 28 N·m (250 in. lbs.). (18) Remove the steering wheel holding tool. (19) Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (20) Inspect system for leaks. (21) Adjust front toe (Refer to 2 - SUSPENSION/ WHEEL ALIGNMENT - STANDARD PROCEDURE). CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important. INSTALLATION - RHD GEAR (11) Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember (Fig. 6). Tighten the M-14 size bolts to a torque of 163 N·m (120 ft. lbs.). Tighten the M-12 size bolts to a torque of 108 N·m (80 ft. lbs.). (12) Install the lower control arm rear bushing retainer bolts through reinforcement on each side of each lower control arm rear bushing. Tighten bolts to a torque of 61 N·m (45 ft. lbs.). (13) Install the two bolts and bushings attaching the reinforcement and rear of cradle crossmember to body of vehicle (Fig. 6). Tighten bolts to a torque of 163 N·m (120 ft. lbs.). (14) If power steering cooler equipped, install the previously disconnected power steering cooler hose on the cooler. Install the clamp. (15) If power steering cooler equipped, install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 3). Install the mounting bolts and tighten to 11 N·m (100 in. lbs.). (16) Install the front tire and wheel assemblies on vehicle. Install the wheel mounting lug nuts and tighten to a torque to 135 N·m (100 ft. lbs.). (1) Install the steering gear up in the front suspension cradle crossmember, leaving room to install intermediate coupler. (2) Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear. (3) Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut (Fig. 12). Hold threaded rod stationary while turning nut. This will pull the roll pin into the intermediate coupler. (4) Install power steering gear on the front suspension cradle. Install the 2 steering gear mounting bolts and nuts. Tighten the M-14 size steering gear to suspension cradle mounting bolt to a torque of 183 N·m (135 ft. lbs.). Tighten the M-12 size steering gear to suspension cradle mounting bolt to a torque of 95 N·m (70 ft. lbs.). (5) Install the heat shield on the steering gear (Fig. 10). (6) Attach the power steering fluid pressure and return hoses to the proper fittings on the steering gear (Fig. 10). Do not fully tighten the fittings at this time. (7) Install the routing clamp with the bolt securing the power steering fluid hoses to the rear of the cradle crossmember (Fig. 11). (8) Using a crowfoot wrench on a torque wrench, tighten the power steering fluid hose tube nuts at the gear to a torque of 31 N·m (275 in. lbs.). (9) Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a socket (Fig. 4), tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket (Fig. 13), tighten the tie rod end attaching nut to a torque of 75 N·m (55 ft. lbs.). (10) If the vehicle is equipped with All-WheelDrive, install the power transfer unit (Refer to 21 TRANSMISSION/TRANSAXLE/POWER TRANSFER UNIT - INSTALLATION). CAUTION: Proper torque on the cradle reinforcement to suspension cradle mounting bolts is very important. 19 - 34 GEAR RS GEAR (Continued) (17) Lower the vehicle to a level were the interior of vehicle is accessible (keeping tires off the ground). (18) With the wheels pointed approximately STRAIGHT-AHEAD, align the intermediate shaft with the steering column coupler. Assemble the steering column shaft coupler onto the steering gear intermediate coupler (Fig. 2). Install steering column coupler to intermediate shaft retaining pinch bolt. Tighten the pinch bolt nut to a torque of 28 N·m (250 in. lbs.). (19) Remove the steering wheel holding tool. (20) Perform the POWER STEERING PUMP INITIAL OPERATION procedure to properly fill and bleed the power steering system. (Refer to 19 STEERING/PUMP - STANDARD PROCEDURE) (21) Inspect for leaks. (22) Adjust front wheel toe (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE). OUTER TIE ROD REMOVAL (1) Loosen inner tie rod to outer tie rod jam nut (Fig. 14). SPECIAL TOOLS Fig. 14 Inner To Outer Tie Rod Jam Nut POWER STEERING GEAR Puller C-3894A 1 2 3 4 5 - INNER TIE ROD SERRATION OUTER TIE ROD JAM NUT OUTER TIE ROD END INNER TIE ROD STEERING KNUCKLE (2) Remove nut attaching outer tie rod end to steering knuckle (Fig. 15). The nut is to be removed from tie rod end by holding tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench. (3) Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool C-3894–A (Fig. 16). (4) Remove outer tie rod end by un-threading it from the inner tie rod. INSTALLATION Remover/Installer Steering Shaft Roll Pin 6831A NOTE: Before installing the outer tie rod, make sure the jam nut is on inner tie rod (Fig. 14). GEAR RS 19 - 35 OUTER TIE ROD (Continued) (3) Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut (Fig. 15). Then using a crowfoot and 11/32 socket (Fig. 17), torque tie rod end attaching nut to 75 N·m (55 ft. lbs.). Fig. 15 Tie Rod End Attaching Nut (Typical) 1 2 3 4 5 - TIE ROD END STEERING KNUCKLE WRENCH SOCKET TIE ROD END STUD Fig. 17 Torquing Tie Rod End Attaching Nut 1 2 3 4 5 - STEERING KNUCKLE TIE ROD END CROWFOOT SOCKET TORQUE WRENCH (4) Tighten tie rod jam nut (Fig. 14) to 75 N·m (55 ft. lbs.) torque. CAUTION: During this procedure do not allow the steering gear boot to become twisted. (5) Adjust the front toe setting on the vehicle (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT STANDARD PROCEDURE). Fig. 16 TIE ROD REMOVAL WITH TOOL C-3894-A 1 - OUTER TIE ROD 2 - SPECIAL TOOL C-3894-A 3 - STEERING KNUCKLE (1) Install outer tie rod onto inner tie rod. (2) Do not tighten jam nut. 19 - 36 PUMP RS PUMP TABLE OF CONTENTS page PUMP DESCRIPTION DESCRIPTION - PUMP (2.4L/3.3L/3.8L ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - PUMP (2.5L DIESEL) . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION . . . REMOVAL REMOVAL - PUMP (2.4L ENGINE) . . . . . . . REMOVAL - PUMP (3.3L/3.8L ENGINE) . . . REMOVAL - PUMP (2.5L DIESEL) . . . . . . . DISASSEMBLY - PUMP (PULLEY) ........ ASSEMBLY - PUMP (PULLEY) . . . . . . . . . . . INSTALLATION INSTALLATION - PUMP (2.4L ENGINE) . . . INSTALLATION - PUMP (3.3L/3.8L ENGINE) INSTALLATION - PUMP (2.5L DIESEL) . . . . SPECIAL TOOLS POWER STEERING PUMP . . . . . . . . . . . . FLUID STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING . . . . FLUID COOLER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . HOSE - POWER STEERING PRESSURE REMOVAL REMOVAL - 2.4L ENGINE . . . . . . . . . . . . . . . . . . . 36 . 37 . 37 . 37 . 37 . . 37 . . . . . . 38 . 40 . 41 . 41 . 42 . . 43 . 43 . . 43 . . 44 . . 44 . . . . . 45 . 45 . 45 . 45 page REMOVAL - 3.3L/3.8L ENGINE ...... INSTALLATION INSTALLATION - 2.4L ENGINE ...... INSTALLATION - 3.3L/3.8L ENGINE . . . HOSE - POWER STEERING RETURN REMOVAL REMOVAL - 2.4L ENGINE . . . . . . . . . . REMOVAL - 3.3L/3.8L ENGINE ...... INSTALLATION INSTALLATION - 2.4L ENGINE ...... INSTALLATION - 3.3L/3.8L ENGINE . . . HOSE - POWER STEERING SUPPLY REMOVAL REMOVAL - 2.4L ENGINE . . . . . . . . . . REMOVAL - 3.3L/3.8L ENGINE ...... INSTALLATION INSTALLATION - 2.4L ENGINE ...... INSTALLATION - 3.3L/3.8L ENGINE . . . RESERVOIR - POWER STEERING FLUID DESCRIPTION DESCRIPTION - 2.4L/3.3L/3.8L ENGINE DESCRIPTION - 2.5L DIESEL . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - 2.4L ENGINE . . . . . . . . . . REMOVAL - 3.3L/3.8L ENGINE ...... REMOVAL - 2.5L DIESEL . . . . . . . . . . . INSTALLATION INSTALLATION - 2.4L ENGINE ...... INSTALLATION - 3.3L/3.8L ENGINE . . . INSTALLATION - 2.5L DIESEL . . . . . . . . . . . . 46 . . . . . 46 . . . . . 47 . . . . . 49 . . . . . 49 . . . . . 50 . . . . . 50 . . . . . 51 . . . . . 51 . . . . . 51 . . . . . 51 . . . . 51 . . . . . 52 . . . . . 52 . . . . . 52 . . . . . 52 . . . . . 52 . . . . . 53 . . . . . 53 . . . . . 53 . . 45 PUMP DESCRIPTION DESCRIPTION - PUMP (2.4L/3.3L/3.8L ENGINE) Hydraulic pressure for the operation of the power steering gear is provided by a belt driven power steering pump. The power steering pump is mounted on the back side of the engine on all engine applications. The pumps are different depending on the engine option. The pump for the 2.4L engine is made out of cast iron and steel (Fig. 1). The pump used on the 3.3L/3.8L engine is made of aluminum (Fig. 2). The pump for the 3.3L/3.8L engine does not have a return fitting as the pump for the 2.4L engine does. The power steering return hose on the 3.3L/3.8L engine goes to the reservoir instead of the pump. PUMP RS 19 - 37 PUMP (Continued) OPERATION The power steering pump is a constant displacement vane type pump. The 2.4L pump has an integral fluid reservoir and there is a secondary remote non-flow reservoir which acts only as a fluid fill and check point. The 3.3L/3.8L pump houses very little fluid and is therefore supplied by a remote flow through reservoir. WARNING Fig. 1 POWER STEERING PUMP (2.4L) 1 2 3 4 5 - PULLEY BRACKET PRESSURE FITTING RETURN FITTING SUPPLY FITTING WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION CAUTION: When the system is open, cap all open ends of the hoses, power steering pump fittings or power steering gear ports to prevent entry of foreign material into the components. STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. Fig. 2 POWER STEERING PUMP (3.3L/3.8L) 1 - SUPPLY FITTING 2 - PRESSURE FITTING 3 - PULLEY DESCRIPTION - PUMP (2.5L DIESEL) Hydraulic pressure for the operation of the power steering gear is provided by a belt driven power steering pump. The power steering pump is mounted front lower right corner of the engine (Fig. 13). The pump has a supply fitting for fluid coming from the reservoir and a pressure port for exiting fluid that is headed for the steering gear. CAUTION: Use only MoparT Automatic Transmission Fluid (MS-9602) in power steering system. Use of other MoparT power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should indicate “FILL RANGE” when the fluid is at a temperature of approximately 21°C to 27°C (70°F to 80°F). (1) Wipe the filler cap and area clean, then remove the cap. 19 - 38 PUMP RS PUMP (Continued) (2) Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. (3) Start the engine and let run for a few seconds, then turn the engine off. (4) Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. (5) Raise the front wheels off the ground. (6) Start the engine. (7) Slowly turn the steering wheel right and left, lightly contacting the wheel stops. (8) Add fluid if necessary. (9) Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. (10) Stop the engine. Check the fluid level and refill as required. (11) If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. Fig. 3 Catalytic Converter to Exhaust Manifold REMOVAL REMOVAL - PUMP (2.4L ENGINE) (1) Remove the (-) negative battery cable from the battery and isolate cable. (2) Remove the cap from the power steering fluid reservoir. (3) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. (4) Raise the vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance. (5) Disconnect the oxygen sensor wiring harness from the vehicle wiring harness at the rear engine mount bracket. NOTE: The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pump from the vehicle. (6) Remove the four bolts and flag nuts securing the catalytic converter from the exhaust manifold (Fig. 3). 1 2 3 4 - CATALYTIC CONVERTER BOLT GASKET FLAG NUT (7) Disconnect all the exhaust system isolators/ hangers from the brackets on the exhaust system (2 at the mufflers and 1 at the resonator) (Fig. 4). (8) Remove the exhaust system by moving it as far rearward, then lowering the front below the crossmember and out of the vehicle. (9) Remove the power steering fluid supply hose from the fitting on the power steering pump. Drain off excess power steering fluid from hose. (10) Move the heat sleeve on the power steering return hose to expose the hose connection at the pump (Fig. 5). Remove the hose from the power steering Pump. Allow the remaining power steering fluid to drain from the power steering pump and reservoir through the removed return hose. (11) Remove the power steering fluid pressure line from the power steering pump (Fig. 6). Drain excess power steering fluid from tube. (12) Remove the fasteners, then the accessory drive splash shield. PUMP RS 19 - 39 PUMP (Continued) Fig. 4 Exhaust System - Typical (All Vehicles) 1 - CATALYTIC CONVERTER 2 - BAND CLAMP 3 - SUPPORTS - MUFFLER 4 - SUPPORT - RESONATOR 5 - RESONATOR 6 - MUFFLER Fig. 6 Power Steering Fluid Pressure And Return Hose 1 - POWER STEERING FLUID RETURN HOSE 2 - POWER STEERING PUMP 3 - POWER STEERING FLUID PRESSURE HOSE Fig. 5 Pressure And Return Hoses - 2.4L 1 2 3 4 5 6 7 8 - POWER STEERING PUMP RETURN HOSE (HEAT SLEEVE COVERED) ROUTING CLAMPS PRESSURE HOSE TUBE NUT RETURN HOSE TUBE NUT CRADLE CROSSMEMBER POWER STEERING GEAR PRESSURE HOSE 19 - 40 PUMP RS PUMP (Continued) (13) Remove the adjuster nut attaching rear of power steering pump to the cast mounting bracket. (Fig. 7) (17) Remove the 3 bolts attaching the front bracket to the power steering pump and separate the power steering pump from the front bracket. (18) If the power steering pump pulley needs to be transferred, (Refer to 19 - STEERING/PUMP - DISASSEMBLY). REMOVAL - PUMP (3.3L/3.8L ENGINE) (1) Remove the (-) negative battery cable from the battery and isolate cable. (2) Remove the wiper module (unit)(Refer to 8 ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL). (3) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Remove the drive belt splash shield. (5) Remove the pressure hose routing bracket bolt (Fig. 9). Fig. 7 Power Steering Pump Attaching Nut 1 2 3 4 - POWER STEERING PUMP MOUNTING BRACKET - FRONT SUSPENSION CRADLE - POWER STEERING PUMP - ADJUSTER NUT (14) Remove the front adjuster nut and the lower pivot bolt (Fig. 8) attaching power steering pump bracket to cast bracket. Fig. 9 Pressure Hose Routing Clamp 1 2 3 4 5 Fig. 8 Pump Front Mounting 1 - ADJUSTER NUT 2 - PIVOT BOLT 3 - PUMP (15) Remove the drive belt from the power steering pump pulley. (16) Remove the power steering pump and the front bracket from the cast bracket on the engine as an assembly through the exhaust tunnel. - PRESSURE HOSE TUBE STEERING GEAR CRADLE CROSSMEMBER DRIVESHAFT ROUTING CLAMP BRACKET (6) lower the vehicle. (7) Remove cap from power steering fluid reservoir. (8) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. (9) Disconnect the pressure hose from the pump (Fig. 10). (10) Disconnect the fluid supply hose from the pump (Fig. 10). (11) Remove the three front mounting bolts through the pulley (Fig. 11) PUMP RS 19 - 41 PUMP (Continued) REMOVAL - PUMP (2.5L DIESEL) (1) Remove the negative (-) battery cable from the battery and isolate cable. (2) Remove the fill cap from the power steering fluid reservoir. (3) Using a siphon pump, remove as much power steering fluid as possible from the fluid reservoir. (4) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (5) Remove the splash shields from below the engine compartment. (6) Remove the accessory drive belt from the power steering pump pulley. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) (7) Disconnect the fluid supply hose from the pump (Fig. 12). (8) Disconnect the pressure hose from the pump (Fig. 12). Fig. 10 Supply And Pressure Hoses At Pump 1 - PRESSURE HOSE AND FITTING 2 - SUPPLY HOSE AND CLAMP 3 - POWER STEERING PUMP Fig. 12 Power Steering Pump - 2.5L Diesel 1 2 3 4 Fig. 11 Pump Mounting 1 - PUMP REAR MOUNTING BOLT (2001 ONLY) 2 - PUMP FRONT MOUNTING BOLT (3) 3 - TIMING CHAIN COVER AND PUMP BRACKET THRU BOLT (2001 ONLY) 4 - PUMP BELT PULLEY 5 - POWER STEERING PUMP 6 - BRACKET (2001 ONLY) - PRESSURE HOSE HOSE CLAMP SUPPLY HOSE POWER STEERING PUMP (9) Remove the bolt fastening the stamped bracket on the rear of the pump to the cast bracket (Fig. 13). (10) Remove the three front mounting bolts through the pulley. (11) Remove the pump from the cast bracket and vehicle. DISASSEMBLY - PUMP (PULLEY) (12) Remove the pump (with pulley) through the engine compartment rocking it over the aluminum bracket. The only serviceable part of the power steering pump is the pulley. The procedure following is for removal and installation of the pulley from the pump once the pump is removed from the vehicle. 19 - 42 PUMP RS PUMP (Continued) ASSEMBLY - PUMP (PULLEY) The only serviceable part of the power steering pump is the pulley. The procedure following is for removal and installation of the pulley from the pump once the pump is removed from the vehicle. (1) Install the pulley with Installer C-4063 (Fig. 15). Do not use the tool adapters. Fig. 13 Pump And Brackets - 2.5L Diesel 1 - CAST BRACKET 2 - STAMPED BRACKET 3 - POWER STEERING PUMP Fig. 15 Pulley Installation (1) Remove the power steering pump from the vehicle. Refer to Removal And Installation in this section of the service manual. (2) Remove the pulley from the shaft of the power steering pump using Puller C-4333 (Fig. 14). 1 - POWER STEERING PUMP DRIVE PULLEY 2 - SPECIAL TOOL C-4063–A (2) Ensure that the tool and the pulley remain aligned with the pump shaft. Prevent the pulley from being cocked on the shaft. (3) Install the pulley until it is flush with the end of the power steering pump shaft (Fig. 16). Fig. 14 Pulley Removal 1 - POWER STEERING PUMP DRIVE PULLEY 2 - SPECIAL TOOL C-4333 CAUTION: Do not hammer on power steering pump pulley. This will damage the pulley and the power steering pump. (3) Replace pulley if it is found to be bent, cracked, or loose. Fig. 16 Pulley To Pump Shaft Location 1 2 3 4 - PULLEY PUMP BODY PUMP SHAFT HUB (4) Install the power steering pump on the vehicle. PUMP RS 19 - 43 PUMP (Continued) INSTALLATION INSTALLATION - PUMP (2.4L ENGINE) (1) Install power steering pump back in vehicle using the reverse order of its removal through the exhaust tunnel of the vehicle. (2) Install the power steering pump on its cast mounting bracket (Fig. 7), then install the nut and bolt attaching the front bracket to the cast bracket (Fig. 8). Do not fully tighten at this time.. (3) Install the rear nut (Fig. 7). (4) Install the power steering pump drive belt on pulley and adjust (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (5) Tighten the two adjustment slot bolts and the one pivot bolt to 54 N·m (40 ft. lbs.) torque. (6) Install the accessory drive splash shield. NOTE: Before installing power steering fluid pressure hose on power steering pump, inspect the O-ring on the pressure hose for damage and replace if necessary. (7) Install the power steering fluid pressure line onto the output fitting of the power steering pump (Fig. 6). Tighten the pressure line to pump fitting tube nut to a torque of 31 N·m (275 in. lbs.). (8) Install the power steering fluid low pressure return hose on the power steering pump low pressure fitting (Fig. 6). Be sure hose clamps are properly reinstalled. (9) Install the power steering fluid supply hose on the power steering pump fluid fitting. Be sure hose is clear of accessory drive belts all hose clamps are properly reinstalled. CAUTION: Heat sleeve must cover entire rubber portion of return hose to ensure desired thermal protection from exhaust. (10) Properly position the protective heat sleeve over the power steering return hose. Securely tie strap the heat sleeve to the power steering hose to keep in it’s proper position. (11) Install the exhaust system (Fig. 4). Install all exhaust system isolators/hangers on the exhaust system brackets, then the four bolts and flag nuts (Fig. 3). (12) Connect the oxygen sensor wiring harness to the vehicle wiring harness. (13) Lower vehicle. (14) Connect the negative battery cable on the negative battery post. (15) Perform the POWER STEERING PUMP INITIAL OPERATION procedure to properly fill and bleed the power steering system. (Refer to 19 STEERING/PUMP - STANDARD PROCEDURE) (16) Inspect for leaks. INSTALLATION - PUMP (3.3L/3.8L ENGINE) (1) Install power steering pump back in vehicle using the reverse order of its removal through the engine compartment of the vehicle. (2) Install the power steering pump on its mounting bracket. (3) Install the 3 front power steering pump mounting bolts (Fig. 11). Tighten the 3 front power steering pump mounting bolts to a torque of 54 N·m (40 ft. lbs.). NOTE: Before installing power steering pressure hose on power steering pump, inspect the O-ring on the power steering pressure hose for damage and replace if required. (4) Install the power steering fluid pressure line into the pressure output fitting of the power steering pump (Fig. 10). Do not fully tighten tube nut at this time. (5) Install the power steering fluid supply hose on the power steering pump supply fitting (Fig. 10). Be sure hose clamp is properly installed. (6) Raise the vehicle. (7) Install the routing clip on the engine for the pressure hose (Fig. 9) and tighten fastener. (8) Install the serpentine drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (9) Install the drive belt splash shield. (10) Lower the vehicle. (11) Tighten the pressure line to pump pressure fitting tube nut to a torque of 31 N·m (275 in. lbs.). (12) Install the wiper module (unit)(Refer to 8 ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - INSTALLATION). (13) Connect the negative battery cable on the negative battery post. (14) Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE). (15) Inspect for leaks. INSTALLATION - PUMP (2.5L DIESEL) (1) Install the power steering pump on its cast mounting bracket. (2) Install the three front power steering pump mounting bolts. Tighten the mounting bolts to a torque of 54 N·m (40 ft. lbs.). (3) Install the rear mounting bolt fastening the stamped bracket to the cast bracket (Fig. 13). Tighten the mounting bolt to a torque of 54 N·m (40 ft. lbs.). 19 - 44 PUMP RS PUMP (Continued) NOTE: Before installing power steering pressure hose on power steering pump, inspect the O-ring on the power steering pressure hose for damage and replace if required. (4) Install the power steering fluid pressure hose fitting into the pressure port of the power steering pump (Fig. 12). Tighten the pressure line to pump fitting tube nut to a torque of 31 N·m (275 in. lbs.). (5) Install the power steering fluid supply hose on the power steering pump supply fitting (Fig. 12). Be sure hose clamp is properly reinstalled. (6) Install the accessary drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (7) Install the splash shields below the engine compartment. (8) Lower the vehicle. (9) Connect the negative (-) battery cable on the negative battery post. (10) Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE). (11) Inspect for leaks. SPECIAL TOOLS POWER STEERING PUMP FLUID STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS AND TO ENSURE ACCURATE FLUID LEVEL READING. The fluid level can be read on the exterior of the power steering fluid reservoir. The fluid level should be within the “FILL RANGE” when the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F) (Fig. 17). Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris. Do not overfill the power steering system. Use only Mopart ATF+4 Automatic Transmission Fluid (MS-9602) in the power steering system. For additional information on Automatic Transmission Fluid, (Refer to LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION). CAUTION: Use only MoparT ATF+4 Automatic Transmission Fluid (MS-9602). Use of other MoparT power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Installer C-4063B Fig. 17 Power Steering Fluid Reservoir Puller C-4333 PUMP RS 19 - 45 FLUID COOLER DESCRIPTION All models (except 2.5L Diesel) are equipped with a cooler for the power steering system fluid. The power steering fluid cooler is located on the front suspension cradle crossmember reinforcement (Fig. 18). There are two different size coolers depending on model and options. There is a standard 6-inch and an 8-inch. OPERATION The purpose of the power steering fluid cooler is to keep the temperature of the power steering system fluid from rising to a level that would affect the performance of the power steering system. The cooler used on this vehicle is referred to as a fluid-to-air type cooler. This means that the air flow across the tubes (and fines surrounding them) of the cooler is used to extract the heat from the cooler which it has absorbed from the power steering fluid flowing through it. The cooler is placed in the power steering fluid return line, between the steering gear and the power steering fluid reservoir. REMOVAL (1) Using a siphon pump, remove as much fluid as possible from the power steering fluid reservoir. (2) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (3) Remove the hose clamps at the cooler and remove the hoses from the cooler inlet and outlet tubes. (4) Remove the 2 bolts attaching the power steering cooler cradle crossmember reinforcement (Fig. 18). Remove the cooler. INSTALLATION (1) Install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 18). Install the mounting bolts and tighten to 11 N·m (100 in. lbs.). (2) Install power steering fluid hoses on the cooler. Be sure hose clamps are installed on hose past the upset bead on the power steering cooler tubes. Fig. 18 Power Steering Cooler 1 - CRADLE CROSSMEMBER REINFORCEMENT 2 - POWER STEERING COOLER (3) Lower the vehicle to a point where front tires are just off the ground. (4) Perform Power Steering Pump Initial Operation procedure. (Refer to 19 - STEERING/PUMP STANDARD PROCEDURE) HOSE - POWER STEERING PRESSURE REMOVAL REMOVAL - 2.4L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. (Refer to 19 - STEERING/PUMP WARNING)(Refer to 19 - STEERING/PUMP - CAUTION) (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. 19 - 46 PUMP RS HOSE - POWER STEERING PRESSURE (Continued) (3) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Remove front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - REMOVAL) (5) Place an oil drain pan under vehicle to catch power steering fluid. (6) Back out pressure hose tube nut at power steering pump pressure fitting and remove hose from pump (Fig. 19). (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. (3) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Remove front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - REMOVAL) (5) Remove two bolts securing pressure hose routing clamps to suspension cradle crossmember and steel reinforcement (Fig. 20). (6) Place an oil drain pan under vehicle to catch draining power steering fluid. (7) Disconnect pressure hose at power steering gear (Fig. 20). (8) Remove pressure hose routing bracket bolt at engine (Fig. 21). Bolt can be accessed through hole in cradle crossmember (Fig. 22). (9) Disconnect pressure hose tube nut at power steering pump (Fig. 21). (10) Remove power steering fluid pressure hose from vehicle. INSTALLATION INSTALLATION - 2.4L ENGINE Fig. 19 PRESSURE AND RETURN HOSES - 2.4L 1 2 3 4 5 6 7 8 - POWER STEERING PUMP RETURN HOSE (HEAT SLEEVE COVERED) ROUTING CLAMPS PRESSURE HOSE TUBE NUT RETURN HOSE TUBE NUT CRADLE CROSSMEMBER POWER STEERING GEAR PRESSURE HOSE (7) Remove bolt attaching right routing clamp to front suspension cradle crossmember (Fig. 19). Remove pressure hose from clamp. (8) Back out pressure hose tube nut at power steering gear and remove hose from gear (Fig. 19). (9) Remove power steering fluid pressure hose from vehicle. REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. (Refer to 19 - STEERING/PUMP - WARNING)(Refer to 19 - STEERING/PUMP - CAUTION) (1) Remove any used O-rings from ends of power steering hose. (2) Using a lint free towel, wipe clean hose ends, power steering pump pressure outlet fitting and steering gear port. (3) Install new O-rings on ends of power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. CAUTION: Use care not to bend tube ends of power steering hoses when installing. Leaks and restrictions may occur. CAUTION: Power steering fluid hoses must remain away from exhaust system and must not come in contact with any unfriendly surfaces on vehicle. (4) Route hose up through cradle crossmember toward power steering pump avoiding tight bends or kinking. (5) Install power steering pressure hose end into pump pressure outlet fitting (Fig. 19). Thread tube nut into outlet fitting, but do not tighten at this time. (6) Route hose behind cradle crossmember and start hose end into gear port. Do not tighten hose tube nut at this time. PUMP RS 19 - 47 HOSE - POWER STEERING PRESSURE (Continued) Fig. 20 HOSES TO POWER STEERING GEAR - 3.3L/3.8L ENGINE 1 2 3 4 5 6 7 - RETURN HOSE (TO RESERVOIR) PRESSURE HOSE (FROM PUMP) CRADLE CROSSMEMBER PRESSURE HOSE ROUTING CLAMP RETURN HOSE ROUTING CLAMP PRESSURE HOSE TUBE NUT POWER STEERING GEAR 8 - ABS BRACKET 9 - ROUTING CLIP 10 - LEAK DETECTION PUMP FILTER 11 - RETURN HOSE TUBE NUT 12 - ROUTING CLIP (7) Install hose into right routing clamp (Fig. 19), then install mounting bolt into cradle crossmember. Tighten bolt to 23 N·m (200 in. lbs.) torque. Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (12) Inspect system for leaks. CAUTION: When tightening and torquing the pressure hose at the power steering pump, the pressure hose is to be rotated against the fluid return hose fitting on the pump. INSTALLATION - 3.3L/3.8L ENGINE (8) Tighten pressure hose tube nuts at pump and gear to 31 N·m (275 in. lbs.) torque. (9) Install front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - INSTALLATION) (10) Lower vehicle. (11) Fill and bleed the power steering system using the Power Steering Pump Initial Operation (1) Remove any used O-rings from ends of power steering hose. (2) Using a lint free towel, wipe clean hose ends, power steering pump pressure outlet fitting and steering gear port. (3) Install new O-rings on ends of power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. CAUTION: Use care not to bend tube ends of the power steering hoses when installing. Leaks and restrictions may occur. 19 - 48 PUMP RS HOSE - POWER STEERING PRESSURE (Continued) Fig. 21 RESERVOIR AND HOSES - 3.3L/3.8L 1 2 3 4 - RESERVOIR ROUTING CLIP (2001 ONLY) SUPPLY HOSE POWER STEERING PUMP 5 - PRESSURE HOSE (TO GEAR) 6 - ROUTING BRACKET 7 - RETURN HOSE (FROM GEAR) CAUTION: Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces on the vehicle. Fig. 22 PRESSURE HOSE ROUTING CLAMP 1 2 3 4 5 - PRESSURE HOSE TUBE STEERING GEAR CRADLE CROSSMEMBER DRIVESHAFT ROUTING CLAMP BRACKET (4) Route hose up behind engine toward pump avoiding tight bends or kinking. (5) Install power steering pressure hose end into pump pressure outlet fitting (Fig. 21). Thread tube nut into outlet fitting, but do not tighten at this time. (6) Attach pressure hose routing bracket to engine (Fig. 21). Tighten bolt to 23 N·m (200 in. lbs.) torque. (7) Tighten hose tube nut at pump outlet fitting to 31 N·m (275 in. lbs.) torque. (8) Route hose behind cradle crossmember and start hose end into gear port. Do not tighten hose tube nut at this time. (9) Attach hose to suspension cradle crossmember and steel reinforcement using two routing clamps and bolts (Fig. 20). Tighten clamp bolt at steel reinforcement to 11 N·m (100 in. lbs.) torque. Tighten clamp bolt at cradle crossmember to 23 N·m (200 in. lbs.) torque. PUMP RS 19 - 49 HOSE - POWER STEERING PRESSURE (Continued) (10) Tighten hose tube nut at power steering gear port to 31 N·m (275 in. lbs.) torque. (11) Install front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - INSTALLATION) (12) Lower vehicle. (13) Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (14) Inspect system for leaks. HOSE - POWER STEERING RETURN REMOVAL REMOVAL - 2.4L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. (Refer to 19 - STEERING/PUMP WARNING)(Refer to 19 - STEERING/PUMP - CAUTION) (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. (3) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Remove front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - REMOVAL) (5) Place an oil drain pan under vehicle to catch power steering fluid. (6) Cut tie-strap securing insulating heat sleeve to power steering fluid return hose near power steering pump. Pull back heat sleeve to expose hose clamp. (7) Remove clamp, then return hose from power steering pump (Fig. 19). (8) Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement (Fig. 23). (9) Remove bolts attaching routing clamps to front suspension cradle crossmember (Fig. 19). Remove return hose from clamps. (10) Back out return hose tube nut at power steering gear and remove hose (Fig. 19). REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. (Refer to 19 - STEERING/PUMP - WARNING)(Refer to 19 - STEERING/PUMP - CAUTION) (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. (3) Place an oil drain pan under vehicle to catch any draining power steering fluid. (4) Remove clamp attaching return hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 21). (5) Follow return hose downward and open retainer at ABS bracket (Fig. 20). Remove hose tube from retainer. (6) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (7) Remove front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - REMOVAL) (8) Remove bolt securing return hose routing clamp to suspension cradle crossmember (Fig. 20). (9) Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement (Fig. 23). Fig. 23 POWER STEERING COOLER 1 - CRADLE CROSSMEMBER REINFORCEMENT 2 - POWER STEERING COOLER (10) Disconnect return hose at power steering gear (Fig. 20). (11) Remove power steering fluid return hose with cooler from vehicle. 19 - 50 PUMP RS HOSE - POWER STEERING RETURN (Continued) INSTALLATION INSTALLATION - 2.4L ENGINE (1) Remove any used O-rings from ends of power steering hose. (2) Using a lint free towel, wipe clean hose ends, power steering pump fitting and steering gear port. (3) Install new O-ring on power steering gear end of return hose. Lubricate O-ring using clean power steering fluid. CAUTION: Use care not to bend tube ends of the power steering hoses when installing. Leaks and restrictions may occur. CAUTION: If a new return hose is being installed and it does not have an insulating heat sleeve installed, the heat shield from the original hose must be transferred before hose installation. (4) Route hose along rear of cradle crossmember and start gear end of hose into gear port. Do not tighten hose tube nut at this time. (5) Attach hose to suspension cradle crossmember using two routing clamps and bolts (Fig. 19). Tighten clamp bolts to 23 N·m (200 in. lbs.) torque. (6) Tighten return hose tube nut at power steering gear port to 31 N·m (275 in. lbs.) torque. (7) Install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 23). Install the mounting bolts and tighten to 11 N·m (100 in. lbs.). CAUTION: Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces on the vehicle. (8) Route pump end of hose over cradle crossmember toward pump avoiding tight bends or kinking. (9) Install return hose onto power steering pump return fitting and secure with hose clamp (Fig. 19). Tighten the screw-type clamp to a torque of 2 N·m (18 in. lbs.). CAUTION: To prevent overheating of power steering fluid return hose, protective heat shield sleeve must cover entire rubber hose. (10) Slide insulating heat shield up over the clamp on the return hose and tie-strap it in place. (11) Install front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - INSTALLATION) (12) Lower vehicle. (13) Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (14) Inspect system for leaks. INSTALLATION - 3.3L/3.8L ENGINE (1) Remove any used O-rings from ends of power steering hose. (2) Using a lint free towel, wipe clean hose ends and power steering gear hose port. (3) Install a new O-ring on gear port end of power steering fluid hose. Lubricate O-ring using clean power steering fluid. CAUTION: Use care not to bend tube ends of the power steering hoses when installing. Leaks and restrictions may occur. CAUTION: Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces on the vehicle. (4) Route hose (with cooler attached) up toward reservoir avoiding tight bends or kinking. (5) Start steering gear end of hose into gear port. Do not tighten hose tube nut at this time. (6) Attach return hose tubes to suspension cradle crossmember using routing clamp and bolt (Fig. 20). Tighten clamp bolt to 23 N·m (200 in. lbs.) torque. (7) Install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 23). Install the mounting bolts and tighten to 11 N·m (100 in. lbs.). When installing mounting bolts, include pressure hose routing clamp. (8) Tighten hose tube nut at power steering gear port to 31 N·m (275 in. lbs.) torque. (9) Install front emissions vapor canister. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/VAPOR CANISTER - INSTALLATION) (10) Lower vehicle. (11) Install return hose tube into retainer on ABS bracket (Fig. 20). Close the bracket. (12) Install return hose onto reservoir (Fig. 21). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. (13) Fill and bleed power steering system using the Power Steering Pump Initial Operation Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (14) Inspect system for leaks. PUMP RS HOSE - POWER STEERING SUPPLY REMOVAL REMOVAL - 2.4L ENGINE (1) Remove filler cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. (3) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Remove hose clamp securing supply hose to power steering pump, then remove supply hose from pump fitting. (5) Lower vehicle. (6) Remove hose clamp attaching power steering fluid supply hose to power steering fluid reservoir, then remove supply hose. (7) Remove the power steering fluid supply hose from the vehicle. REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. (Refer to 19 - STEERING/PUMP WARNING)(Refer to 19 - STEERING/PUMP - CAUTION) (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. (3) Place an oil drain pan under vehicle to catch any draining power steering fluid. (4) Remove clamp attaching supply hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 21). (5) Pull upward on hose routing clip releasing it from bracket on cylinder head cover (Fig. 21). NOTE: It may be necessary to remove air cleaner housing to gain greater access to supply hose at power steering pump. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING REMOVAL) (6) Remove clamp attaching supply hose to power steering pump. Disconnect hose from pump and remove from vehicle (Fig. 21). 19 - 51 INSTALLATION INSTALLATION - 2.4L ENGINE (1) Install and correctly route power steering fluid supply hose from remote fluid reservoir to power steering pump. (2) Install fluid supply hose onto power steering fluid reservoir. Install hose clamp. Be sure hose clamp is installed past bead on fluid reservoir fitting. (3) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Install power steering fluid supply hose on power steering pump supply fitting. Install hose clamp. Be sure hose clamp is installed past bead on pump fitting. (5) Lower vehicle. (6) Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (7) Inspect system for leaks. INSTALLATION - 3.3L/3.8L ENGINE (1) Install supply hose onto supply fitting on power steering pump (Fig. 21). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. (2) Align routing clip located toward center of supply hose with hole in bracket on cylinder head cover and push into place (Fig. 21). (3) Install supply hose onto reservoir (Fig. 21). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. (4) Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (5) Inspect system for leaks. RESERVOIR - POWER STEERING FLUID DESCRIPTION DESCRIPTION - 2.4L/3.3L/3.8L ENGINE All vehicles use a remote mounted power steering fluid reservoir. The power steering fluid reservoir is mounted to the engine near the battery (Fig. 24). 19 - 52 PUMP RS RESERVOIR - POWER STEERING FLUID (Continued) (4) Remove clamp attaching supply hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 21). (5) Remove clamp attaching return hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 21). (6) Remove bolts and nut securing reservoir in place (Fig. 21). (7) Remove reservoir. REMOVAL - 2.5L DIESEL Fig. 24 Power Steering Fluid Reservoir (Typical) DESCRIPTION - 2.5L DIESEL All vehicles use a remote mounted power steering fluid reservoir. The power steering fluid reservoir is mounted to a bracket on the engine manifold (Fig. 25). (1) Open hood. (2) Remove engine cover. (3) Remove the filler cap from remote power steering fluid reservoir. (4) Siphon as much fluid as possible from the fluid reservoir. (5) Remove the clamp attaching the return hose to the power steering fluid reservoir. Disconnect hose from reservoir (Fig. 25). OPERATION The power steering fluid reservoir stores and supplies power steering fluid for the power steering system. REMOVAL REMOVAL - 2.4L ENGINE (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. (3) Open retainer on side of reservoir and remove cables from retainer. (4) Remove clamp attaching supply hose to power steering fluid reservoir. Disconnect hose from reservoir. (5) Remove bolts and nut securing reservoir in place. (6) Remove reservoir. REMOVAL - 3.3L/3.8L ENGINE (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. (3) Open retainer on side of reservoir and remove cables from retainer. Fig. 25 Reservoir And Hoses - 2.5L Diesel 1 - POWER STEERING FLUID RESERVOIR 2 - RESERVOIR BRACKET 3 - SUPPLY HOSE BRACKET 4 - RETURN HOSE FROM GEAR 5 - ROUTING CLIP 6 - PRESSURE HOSE TO GEAR 7 - SUPPLY HOSE (PUMP END) 8 - PRESSURE HOSE (PUMP END) 9 - SUPPLY HOSE 10 - RETURN HOSE PUMP RS 19 - 53 RESERVOIR - POWER STEERING FLUID (Continued) (6) Remove the clamp attaching the supply hose to the power steering fluid reservoir. Disconnect hose from reservoir (Fig. 25). (7) Press the tang on the reservoir mounting bracket retaining the reservoir to the bracket, then pull upward on reservoir and remove it from the bracket. INSTALLATION INSTALLATION - 2.4L ENGINE (1) Place reservoir into position on engine. (2) Install reservoir mounting bolts and nut. Tighten fasteners to 12 N·m (105 in. lbs.) torque. (3) Install supply hose onto reservoir. Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. (4) Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (5) Inspect system for leaks. INSTALLATION - 3.3L/3.8L ENGINE (1) Place reservoir into place on engine (Fig. 21). (2) Install reservoir mounting bolts and nut (Fig. 21). Tighten fasteners to 12 N·m (105 in. lbs.) torque. (3) Install supply hose onto reservoir (Fig. 21). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. (4) Install return hose onto reservoir (Fig. 21). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. (5) Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure. (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE) (6) Inspect system for leaks. INSTALLATION - 2.5L DIESEL (1) Align the guide on the rear of the reservoir with the mounting bracket and push reservoir downward until reservoir clicks into place in the bracket. (2) Install the supply hose onto the reservoir (Fig. 25). Slide the hose clamp into position on the fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. (3) Install the return hose onto the reservoir (Fig. 25). Slide the hose clamp into position on the fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. (4) Fill the fluid reservoir to the proper level with the correct Mopart power steering fluid or equivalent. (5) Start the engine and let run for a few seconds, then turn the engine off. (6) Add fluid as necessary. (7) Install the filler cap. (8) Install engine cover. CLUTCH RS 6-1 CLUTCH TABLE OF CONTENTS page CLUTCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - CLUTCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - DRIVE PLATE MISALIGNMENT . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - CLUTCH COVER AND DISC RUNOUT . . . . . . . . . . DIAGNOSIS AND TESTING - CLUTCH CHATTER COMPLAINTS . . . . . . . . . . . . . SPECIAL TOOLS - T850 TRANSAXLE .... CLUTCH RELEASE LEVER AND BEARING REMOVAL ......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER - RHD REMOVAL ......................... ....1 ....3 ....5 ....6 ....6 ....6 ....6 ....7 ....8 page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MASTER CYLINDER - LHD REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 MODULAR CLUTCH ASSY - 2.4L GAS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 SLAVE CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 CLUTCH DISC AND PRESSURE PLATE - 2.5L TD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 CLUTCH DESCRIPTION CLUTCH COMPONENTS Models equipped with a 2.4L Gas engine utilize a modular clutch assembly (Fig. 1). The modular clutch consists of a single, dry-type clutch disc, a diaphragm style clutch cover, and an integrated flywheel. The clutch cover (pressure plate) is riveted to the flywheel, and therefore can only be serviced as an assembly. Models equipped with the 2.5L Turbo Diesel engine utilize a conventional clutch system (Fig. 2). This system consists of a flywheel, clutch disc, and clutch cover (pressure plate), which is fastened to the flywheel, capturing the clutch disc within. Each component is individually serviceable, however it is highly recommended that the clutch cover and disc be replaced as a set. Fig. 1 Modular Clutch Assembly—2.4L Gas Engines 1 - MODULAR CLUTCH ASSEMBLY 6-2 CLUTCH RS CLUTCH (Continued) Fig. 2 Clutch Disc and Pressure Plate—2.5L TD Engines 1 - FLYWHEEL 2 - DISC 3 - PRESSURE PLATE RELEASE SYSTEM All models utilize a hydraulic clutch release system, conisting of a clutch master cylinder attached to the clutch pedal (Fig. 3), and a slave cylinder fastened to the transaxle which operates the clutch release lever (Fig. 4). When the driver depresses the clutch pedal, the master cylinder pushrod travels through the cylinder bore, displacing fluid through the master cylinder plumbing. This fluid displacement forces the slave cylinder piston to travel, forcing the clutch release bearing into the clutch diaphragm spring via the release lever and leverage (Fig. 5). This releases the clamping force on the clutch disc, allowing the engine crankshaft to rotate independently from the transaxle input shaft. Fig. 3 Clutch Master Cylinder—Typical CLUTCH RS 6-3 CLUTCH (Continued) Fig. 5 Release Bearing and Lever 1 - RELEASE LEVER 2 - RELEASE BEARING Fig. 4 Slave Cylinder Removal/Installation 1 2 3 4 - MOUNTING HOLE - SLAVE CYLINDER - ACCESS HOLE - NYLON ANTI-ROTATION TAB DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - CLUTCH SYSTEM Clutch problem diagnosis will generally require a road test to determine the type of fault. Component inspection will then determine the problem after road testing. Drive the vehicle at normal speeds during road test. Shift the transaxle through all gear ranges and observe clutch action. If chatter, grab, slip, or improper release is experienced, remove and inspect the clutch components. If the problem is noise or hard shifting, further diagnosis may be needed. The transaxle or other driveline components may actually be at fault. SERVICE DIAGNOSIS - CLUTCH GRAB/CHATTER CONDITION CLUTCH DISC FACING COVERED WITH OIL OR GREASE POSSIBLE CAUSES CORRECTION Oil leak at engine rear main or transaxle input shaft seal. Correct leak and replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Too much grease applied to splines of disc and input shaft. Apply lighter coating of grease to splines. NO FAULT FOUND WITH CLUTCH COMPONENTS Problem actually related to suspension or driveline component. Further diagnosis required. Check engine/transmission mounts, suspension attaching parts and other driveline components as needed. Engine related problems. Check EFI and ignition systems. PARTIAL ENGAGEMENT OF CLUTCH DISC Clutch cover, spring, or release fingers bent, distorted (rough handling, improper assembly). Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). 6-4 CLUTCH RS CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch disc damaged or distorted. Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Clutch misalignment. Verify modular clutch pilot plate alignment to crankshaft. Replace the modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD) if the pilot plate is loose or bent. Improper transaxle-to-engine installation. Verify transaxle is properly installed to engine. SERVICE DIAGNOSIS - CLUTCH SLIPS CONDITION DISC FACING WORN OUT CLUTCH DISC FACING CONTAMINATED WITH OIL OR GREASE CLUTCH IS RUNNING PARTIALLY DISENGAGED CLUTCH DISC FACINGS HAVE FRACTURED INTO SMALL PIECES POSSIBLE CAUSES CORRECTION Normal wear. Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Driver frequently rides (slips) clutch, results in rapid wear, overheating. Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Insufficient clutch cover diaphragm spring tension Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Leak at rear main oil seal or transaxle input shaft seal Replace leaking seals. Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Excessive amount of grease applied to input shaft splines Apply less grease to input shaft. Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Road splash, water entering housing Seal housing. Inspect clutch assembly. Release bearing sticking or binding, does not return to normal running position. Verify that bearing is actually binding. Then, replace bearing and transmission front bearing retainer if sleeve surface is damaged. Clutch pedal not returning to static position. Inspect pedal assembly for damage and/or obstructions. Replace componnents as necessary. Clutch master cylinder or pushrod damaged causing high preload. Replace clutch master cylinder assembly. Slave cylinder binding or stuck. Replace slave cylinder. Leak at rear main or transaxle input shaft seal Replace seal. Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD).. Excessive heat from slippage Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). CLUTCH RS 6-5 CLUTCH (Continued) SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE CONDITION CLUTCH DISC BINDS ON INPUT SHAFT SPLINES POSSIBLE CAUSES CORRECTION Clutch disc hub splines damaged during installation Clean, smooth, and lubricate disc and shaft splines. Replace modular clutch assembly, or clutch disc, and/or input shaft if splines are severely damaged. Input shaft splines rough, damaged. Clean input shaft splines. Then lube. Corrosion or rust formations on splines of input shaft and disc Clean input shaft splines and disc splines, then lube CLUTCH DISC RUSTED TO FLYWHEEL AND/OR PRESSURE PLATE Occurs in vehicles stored or not driven for extended period of time. Also occurs after steam cleaning if vehicle is not used for extended period. Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). CLUTCH WILL NOT DISENGAGE PROPERLY Disc bent, distorted during transaxle installation Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Clutch cover diaphragm spring damaged during transaxle installation Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Release fork bent, loose, or damaged Replace fork if worn or damaged Air in clutch hydraulic circuit. Allow system to self-bleed or replace hydraulic components. Leak in clutch hydraulic circuit. Replace worn/damaged/leaking hydraulic components. Clutch disc is worn. Replace modular clutch assembly (2.4L models) or clutch cover and disc (2.5L TD models). Clutch pedal requires excessive force (high release load). SERVICE DIAGNOSIS - CLUTCH PEDAL NOISE CONDITION CLUTCH PEDAL SQUEAKS WHEN DEPRESSED TO FLOOR CLUTCH PEDAL SQUEAKS DURING OPERATION POSSIBLE CAUSES CORRECTION Pedal bushings worn out or inadequate lubrication Replace or lubricate bushings at clutch pedal pivot or master cylinder pushrod. Clutch pedal return spring worn out Lubricate or replace return spring Clutch release lever pivot stud has inadequate lubrication Lubricate or replace clutch release lever DIAGNOSIS AND TESTING - DRIVE PLATE MISALIGNMENT Common causes of misalignment are: • Heat warping • Mounting drive plate on a dirty crankshaft flange • Incorrect bolt tightening • Improper seating on the crankshaft shoulder • Loose crankshaft bolts Clean the crankshaft flange before mounting the drive plate. Dirt and grease on the flange surface may misalign the flywheel, causing excessive runout. Use new bolts when mounting drive plate to crankshaft. Tighten drive plate bolts to specified torque only. Over-tightening can distort the drive plate hub causing excessive runout. 6-6 CLUTCH RS CLUTCH (Continued) DIAGNOSIS AND TESTING - CLUTCH COVER AND DISC RUNOUT Check condition of the clutch cover before installation. A warped cover or diaphragm spring will cause grab and/or incomplete release or engagement. Use care when handling the clutch assembly. Impact can distort the cover, diaphragm spring, and release fingers. DIAGNOSIS AND TESTING - CLUTCH CHATTER COMPLAINTS For all clutch chatter complaints, perform the following: (1) Check for loose, misaligned, or broken engine and transmission mounts. If present, they should be corrected at this time. Test vehicle for chatter. If chatter is gone, there is no need to go any further. (2) If chatter persists, check hydraulic clutch release system is functioning properly. (3) Check for loose connections in drivetrain. Correct any problems and determine if clutch chatter complaints have been satisfied. If not: (a) Remove transaxle. (b) Check to see if the release bearing is sticky or binding. Replace bearing, if needed. (c) Check linkage for excessive wear on the pivot stud and fork fingers. Replace all worn parts. (d) Check clutch assembly for contamination (dirt, oil). Replace clutch assembly, if required. (e) Check to see if the clutch disc hub splines are damaged. Replace with new clutch assembly, if necessary. (f) Check input shaft splines for damage. Replace, if necessary. (g) Check for uneven wear on clutch fingers. (h) Check for broken clutch cover diaphragm spring fingers. Replace with new clutch assembly, if necessary. Remover/Installer, 6891 CLUTCH RELEASE LEVER AND BEARING REMOVAL (1) Remove transaxle assembly. (Refer to 21 TRANSMISSION/TRANSAXLE/MANUAL REMOVAL) (2) Remove modular clutch assembly from input shaft (2.4L Gas models only). (3) Grasp clutch release lever and bearing (Fig. 6) with both hands and pull outward using moderate pressure to release lever from pivot ball. SPECIAL TOOLS - T850 TRANSAXLE Fig. 6 Release Bearing and Lever Disconnect Tool, 6638A 1 - RELEASE LEVER 2 - RELEASE BEARING CLUTCH RS CLUTCH RELEASE LEVER AND BEARING (Continued) (4) Separate release bearing from lever. NOTE: Remove release lever pivot ball(s) ONLY if replacement is necessary. (5) Remove pivot ball(s) using slide hammer C-3752 and remover/installer 6891 (Fig. 7). Fig. 8 Pivot Ball Removal/Installation 1 - C-3752 SLIDE HAMMER 2 - REMOVER/INSTALLER 6891 3 - PIVOT BALL Fig. 7 Pivot Ball Removal/Installation 1 - C-3752 SLIDE HAMMER 2 - REMOVER/INSTALLER 6891 3 - PIVOT BALL INSTALLATION (1) If removed, install new release lever pivot ball(s) using slide hammer C-3752 and remover/installer 6891 (Fig. 8) (Fig. 9). (2) Install clutch release bearing to lever. Apply grease to interface points. Make sure release bearing retainers engage lever pocket as shown in (Fig. 10). (3) Apply grease to pivot ball, and on release lever at slave cylinder contact point. Fig. 9 Pivot Ball Position 1 - PIVOT BALL (1) 6-7 6-8 CLUTCH RS CLUTCH RELEASE LEVER AND BEARING (Continued) MASTER CYLINDER - RHD REMOVAL Fig. 10 Release Bearing-to-Lever (1) Disconnect battery negative cable. (2) Remove master cylinder to clutch pedal pin retainer clip. Disengage pushrod from clutch pedal pin (Fig. 13). (3) Disengage master cylinder grommet from cowl panel. (4) Remove battery and tray. (5) Diesel models: Remove windshield wiper module assembly. (Refer to 8 - ELECTRICAL/WIPERS/ WASHERS/WIPER MODULE - REMOVAL) (6) Discharge Air Conditioning system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ REFRIGERANT - STANDARD PROCEDURE) (7) Remove suction/discharge line from evaporator junction block. (8) Using tool 6638A, disconnect clutch hydraulic “quick-connect” fitting (Fig. 12). 1 - RETAINER (2) 2 - RELEASE LEVER 3 - RELEASE BEARING (4) Install clutch release bearing/lever assembly into position by sliding bearing onto input bearing retainer, and using moderate hand pressure to seat release lever to pivot ball(s) (Fig. 11). A “pop” sound should be heard. Verify proper engagement by lightly pulling outward on lever at pivot ball location, and then actuating lever and bearing to ensure proper operation. Fig. 12 Disconnect Quick-Connect Using Tool 6638A 1 - QUICK CONNECT FITTING 2 - TOOL 6638A (9) Remove clutch master cylinder tubing from retainers in engine compartment. (10) Remove clutch master cylinder from dash panel/clutch pedal bracket by rotating 45° clockwise and pulling outward towards engine (Fig. 13). (11) Carefully guide clutch master cylinder and hydraulic plumbing from engine compartment. INSTALLATION Fig. 11 Release Bearing and Lever 1 - RELEASE LEVER 2 - RELEASE BEARING (1) Carefully route master cylinder plumbing into engine compartment as removed and position master cylinder to dash panel hole. (2) Rotate master cylinder 45° clockwise, insert into dash panel hole, engaging clutch pedal bracket. CLUTCH RS 6-9 MASTER CYLINDER - RHD (Continued) MASTER CYLINDER - LHD REMOVAL (1) Disconnect battery cables. (2) Remove instrument panel lower silencer (Fig. 14). Fig. 13 Clutch Master Cylinder at Pedal Bracket 1 2 3 4 - CLUTCH MASTER CYLINDER RETAINER CLIP CLUTCH PEDAL PIN PUSH ROD Rotate master cylinder 45° counter-clockwise, securing it to pedal bracket (Fig. 13). (3) Install and secure grommet to dash panel. (4) Connect pushrod to clutch pedal pin. Install retainer clip (Fig. 13). (5) Secure master cylinder plumbing to retainers in engine compartment. (6) Connect clutch master cylinder plumbing to slave cylinder “quick connect” fitting. An audible “click” should be heard. Verify connection by pulling outward. (7) Connect A/C suction/discharge line to evaporator junction block. (8) Diesel models: Install wiper module assembly. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER MODULE - INSTALLATION) (9) Install battery and tray. (10) Connect battery negative cable (11) Charge Air Conditioning system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE) Fig. 14 Instrument Panel Lower Silencer 1 - INSTRUMENT PANEL LOWER SILENCER (3) Remove knee bolster (Fig. 15). Fig. 15 Knee Bolster 1 - KNEE BOLSTER 6 - 10 CLUTCH RS MASTER CYLINDER - LHD (Continued) (4) Remove clutch retainer clip (Fig. 16). master cylinder pushrod Fig. 17 Disconnect Quick-Connect Using Tool 6638A 1 - QUICK CONNECT FITTING 2 - TOOL 6638A Fig. 16 Master Cylinder Pushrod at Pedal 1 - MASTER CYLINDER PUSHROD 2 - CLUTCH/BRAKE PEDAL ASSEMBLY 3 - PUSHROD RETAINER (5) Disconnect pushrod from clutch pedal (Fig. 16). (6) Remove battery shield. (7) Remove battery. (8) Remove battery tray. (9) Remove windshield wiper module assembly (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER MODULE - REMOVAL). (10) Using Tool 6638A, disconnect clutch master cylinder “quick connect” fitting (Fig. 17). Disengage plumbing retainer from body stud. (11) Remove master cylinder reservoir-to-strut tower nuts (Fig. 18). Reposition reservoir off to side. (12) Remove clutch master cylinder from dash panel by rotating clockwise 45° and removing from dash panel (Fig. 18). (13) Remove master cylinder and plumbing from engine compartment. Use care not to bend or kink plumbing. Note plumbing routing to aid in installation. INSTALLATION (1) Install master cylinder into position, while routing plumbing as originally installed. (2) Insert master cylinder pushrod through dash panel (Fig. 18) and rotate 45° counter-clockwise to secure. Fig. 18 Clutch Master Cylinder Removal/Installation 1 - CLUTCH MASTER CYLINDER 2 - RESERVOIR 3 - NUT (2) (3) Connect master cylinder plumbing quick-connect fitting. An audible “click” should be heard. Verify connection by pulling outward. (4) Install master cylinder reservoir onto strut tower. Install and tighten two (2) master cylinder reservoir-to-strut tower nuts (Fig. 18). CLUTCH RS 6 - 11 MASTER CYLINDER - LHD (Continued) (5) Install windshield wiper module assembly (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER MODULE - INSTALLATION). (6) Install battery tray. (7) Install battery. (8) Install battery shield. (9) Connect master cylinder pushrod to clutch pedal lever (Fig. 16). Install retainer clip. (10) Install knee bolster and instrument panel lower silencer (Fig. 15) (Fig. 14). (11) Connect battery cables. SLAVE CYLINDER REMOVAL (1) Raise vehicle on hoist. Diesel models: Remove underbody splash shield. (2) Using Tool 6638A, disconnect hydraulic clutch circuit quick connect fitting. (3) Remove clutch slave cylinder (Fig. 20) by lifting nylon tab with a small screwdriver, and then depressing cylinder inward towards case and rotating cylinder 60° counter-clockwise. MODULAR CLUTCH ASSY 2.4L GAS REMOVAL (1) Remove transaxle from vehicle. (Refer to 21 TRANSMISSION/TRANSAXLE/MANUAL REMOVAL) (2) Remove modular clutch assembly from input shaft (Fig. 19). Fig. 20 Slave Cylinder Removal/Installation 1 2 3 4 - MOUNTING HOLE - SLAVE CYLINDER - ACCESS HOLE - NYLON ANTI-ROTATION TAB INSTALLATION Fig. 19 Modular Clutch Assembly 1 - MODULAR CLUTCH ASSEMBLY 2 - INPUT SHAFT INSTALLATION (1) Install modular clutch assembly to transaxle input shaft (Fig. 19). (2) Install transaxle to vehicle. (Refer to 21 TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION) (1) Install clutch slave cylinder into position, noting orientation of different sized lugs. While depressing inward, rotate slave cylinder clockwise until nylon locating tab rests in transaxle case cutout, and the hydraulic tube is vertical (Fig. 20). (2) Connect “quick-connect” connection until an audible “click” is heard. Verify connection by pulling outward on connection. (3) Diesel models: Install underbody splash shield. (4) Lower vehicle. 6 - 12 CLUTCH RS CLUTCH DISC AND PRESSURE PLATE - 2.5L TD REMOVAL (1) Remove transaxle assembly. (Refer to 21 TRANSMISSION/TRANSAXLE/MANUAL REMOVAL) (2) Remove six (6) clutch pressure plate-to-flywheel bolts. Remove pressure plate and disc from flywheel (Fig. 21). (3) Inspect flywheel. Resurface/replace as necessary. (4) Inspect clutch release bearing and lever. Replace as necessary. (Refer to 6 - CLUTCH/ CLUTCH RELEASE BEARING - REMOVAL) INSTALLATION (1) Install clutch release bearing and lever (if removed). (Refer to 6 - CLUTCH/CLUTCH RELEASE BEARING - INSTALLATION) (2) Install clutch disc and pressure plate to flywheel (Fig. 21). Install clutch alignment tool, and install and torque pressure plate-to-flywheel bolts to 28 N·m (250 in. lbs.). (3) Install transaxle assembly. (Refer to 21 TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION) Fig. 21 Clutch Disc and Pressure Plate 1 - FLYWHEEL 2 - DISC 3 - PRESSURE PLATE RS CLUTCH FLYWHEEL REMOVAL (1) Remove transaxle assembly. (Refer to 21 TRANSMISSION/TRANSAXLE/MANUAL REMOVAL) (2) Remove clutch pressure plate and disc. (Refer to 6 - CLUTCH/CLUTCH DISC - REMOVAL) (3) Remove flywheel assembly (Fig. 22). INSTALLATION (1) Install NEW flywheel-to-crankshaft bolts by hand. (2) Torque bolts in a criss-cross sequence to 25 N·m (18 ft. lbs.) (Fig. 22). (3) Torque bolts in a criss-cross sequence an additional 60°. (4) Install clutch pressure plate and disc. (Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLATION) (5) Install transaxle assembly. (Refer to 21 TRANSMISSION/TRANSAXLE/MANUAL INSTALLATION) Fig. 22 Flywheel Bolt Torque Sequence 6 - 13 VEHICLE THEFT SECURITY RS 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page VEHICLE THEFT SECURITY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - SENTRY KEY IMMOBILIZER SYSTEM . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY SYSTEM . . . . . . . . . . HOOD AJAR SWITCH REMOVAL ......................... ....1 ....1 ....3 ....3 page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . TRANSPONDER KEY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - TRANSPONDER PROGRAMMING . . . . . . . . . . . . . . . . . . . VTSS/SKIS INDICATOR LAMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....3 ....3 ....3 ....4 ....5 ....5 ....3 VEHICLE THEFT SECURITY OPERATION DESCRIPTION VEHICLE THEFT SECURITY SYSTEM VEHICLE THEFT SECURITY SYSTEM The Vehicle Theft Security System (VTSS) is designed to protect against whole vehicle theft. The system monitors vehicle doors, hood, liftgate, and ignition action for unauthorized operation. The alarm activates: • Sounding of the horn • Flashing of the park and tail lamps • Flashing of the headlamps • An engine kill feature (without SKIS) SENTRY KEY IMMOBILIZER SYSTEM The Sentry Key Immobilizer System (SKIS) is available as a factory-installed option on this vehicle. It is designed to provide passive protection against unauthorized vehicle use by disabling the engine, after two (2) seconds of running, whenever an invalid key is used to start the vehicle. The SKIS is active whenever the ignition is on and does not require any customer intervention. The primary components of the system are the Sentry Key Immobilizer Module (SKIM), Sentry Key (ignition key w/ a transponder molded into the head), indicator light, Body Control Module (BCM), and the Powertrain Control Module (PCM). The SKIM is mounted to the steering column with the molded, integral antenna mounted on the ignition housing. The indicator light, is located in the message center. Upon failure of proper SKIM communication to the PCM, the PCM will shut off fuel after two seconds of run time. The engine will not re-crank on the key cycle that the failure occurred, a full key down sequence must be performed for the engine to crank again. After six consecutive fuel shut-offs, the engine will no longer crank on subsequent key cycles. The failure must be corrected and a valid communication process between the SKIM and the PCM must occur for the engine to crank and start again. The electronics for the VTSS are part of the Body Control Module (BCM). The system is armed when the vehicle is locked using the: • Power door lock switches (with any door ajar) • Remote Keyless Entry transmitter. • Door Cylinder Lock Switches. For vehicles equipped with SKIS, the doors do not have to be locked to enable the fuel shut off feature. After the vehicle is locked and the last door is closed, the set LED indicator in the top cover will flash quickly for 16 seconds, indicating that arming is in progress. If no monitored systems are activated during this period, the system will arm. The LED will extinguish unless the liftgate is open. If the liftgate is open, the LED will flash at a slower rate. This indicates that the system is armed. If fault is detected on any key cylinder input, the indicator LED will remain solid during the arming process, although the system will still arm. If the indicator LED does not illuminate at all upon door closing it indicates that the system is not arming. 8Q - 2 VEHICLE THEFT SECURITY RS VEHICLE THEFT SECURITY (Continued) Passive disarming occurs upon normal vehicle entry by unlocking either door with the ignition key/ remote transmitter. This disarming will also halt the alarm once it has been activated. A tamper alert exists to notify the driver that the VTSS had been activated. This alert consists of 3 horn pulses when the vehicle is disarmed. NOTE: The VTSS will not arm by pushing down the door lock mechanism. This will manually override the system. For Door Cylinder Lock Switch Removal and Installation, refer to Electrical, Power Locks, Door Cylinder Lock Switch. If the VTSS is triggered, the horn will pulse, headlamps/marker lamps will flash, and the VTSS warning lamp will flash. If BCM determines the threat to be false and the VTSS is not triggered again, the system will shut down and rearm itself after three minutes. If a trigger is still active, the alarm will continue for an additional 15 minutes without the horn. The VTSS monitoring portion of the system is split into two sections. The engine compartment section and the passenger compartment section. If a malfunction occurs in the engine compartment section, the passenger compartment section would still arm and function normally. NOTE: If hood is not secure during the arming sequence, the lamp will stay lit and not flash. The system will arm with hood not secured (hood ajar switch closed) and the liftgate open (liftgate ajar switch closed). System will not arm if passenger compartment is not secure (all switches closed) ARMING THE VTSS - METHOD A (1) With the key removed from the ignition lock and any door open (excluding liftgate), actuate one of the following: • Power door lock button to LOCK, • Key fob LOCK button • Door lock key cylinder to locked position. (2) Close all opened doors. Liftgate can remain open. (3) After the last door is closed, an arming timeout period of sixteen seconds will start, then the VTSS will become armed. ARMING THE VTSS - METHOD B Actuating the key fob transmitter LOCK button, key locking the front doors with the doors closed and the ignition locked will begin the arming time-out period. If method A, 16 second time-out sequence was in process when method B was actuated, the 16 sec- ond time-out will restart from the time of the second actuation. If the security lamp does not illuminate at all upon final door closure, it indicates that the system is not arming. The current VTSS status armed or disarmed shall be maintained in memory to prevent battery disconnects from disarming the system. TRIGGERING THE VTSS After the VTSS is armed, the following actions will trigger the alarm: • Opening any door (excluding liftgate). • Opening the hood • Turning the ignition to the ACC, or UNLOCK position. NOTE: When the VTSS is ARMED, the interior power door lock switch “UNLOCK” will be disabled until the vehicle is disarmed. CAUTION: The VTSS indicator LED will trigger and engine will continue to run if the vehicle is equipped with SKIS and the proper key is used to start the vehicle. This condition will occur if the VTSS has been triggered. If valid key is used, VTSS will disarm SENTRY KEY IMMOBILIZER SYSTEM The SKIS includes keys from the factory which are pre-programmed. Each SKIM will recognize a maximum of eight Sentry Keys. If the customer would like to own additional keys other than those provided with the vehicle, they can be purchased from any authorized dealer. These keys must be programmed to the SKIM on the vehicle in order for the system to recognize them as valid keys. This can be done by the dealer with a DRB IIIt scan tool or by a customer if this feature is available in their market and they have two (2) valid keys already available to them. Refer to the Service Procedures portion of this system for additional details. The SKIS performs a self-test each time the ignition switch is turned to the ON position and will store Diagnostic Trouble Codes (DTC’s) if a system malfunction is detected. The SKIS can be diagnosed and any stored DTC’s can be retrieved using a DRB IIIt scan tool as described in the appropriate Body Diagnostic Procedures manual. VEHICLE THEFT SECURITY RS 8Q - 3 VEHICLE THEFT SECURITY (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - SENTRY KEY IMMOBILIZER SYSTEM WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS, WARNINGS, BEFORE ATTEMPTING COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The following tests may not prove conclusive in the diagnosis of this system. The most reliable, efficient, and accurate means to diagnose the Sentry Key Immobilizer System involves the use of a DRB IIIT scan tool. Refer to the proper Body Diagnostic Procedures Manual. The Sentry Key Immobilizer System (SKIS) and the Programmable Communication Interface (PCI) bus network should be diagnosed using a DRB IIIt scan tool. The DRB IIIt will allow confirmation that the PCI bus is functional, that the Sentry Key Immobilizer Module (SKIM) is placing the proper messages on the PCI bus, and that the Powertrain Control Module (PCM) is receiving the PCI bus messages. Refer to the proper Body Diagnostic Procedures manual, and Wiring Diagrams for complete circuit descriptions and diagrams. (1) Check the fuses in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. (2) Disconnect and isolate the battery negative remote cable from the remote terminal. Unplug the wire harness connector at the SKIM. Check for continuity between the ground circuit cavity of the SKIM wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. (3) Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the SKIM wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the fuse in the IPM as required. (4) Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the SKIM wire harness connector. If OK, use a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual to complete the diagnosis of the SKIS. If not OK, repair the open circuit to the fuse in the IPM as required. DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY SYSTEM 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. Using a DRB IIIt scan tool. Refer to the proper Body Diagnostic Procedures Manual for test procedures. HOOD AJAR SWITCH REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Using a small flat blade screwdriver, pry trigger switch from the bracket on the left fender well. (3) Disconnect the hood ajar switch from the wire connector and remove from vehicle. INSTALLATION (1) Connect the hood ajar switch to the wire conector. (2) Press the hood ajar switch into position on the bracket located on the left inner fender well. (3) Reconnect the battery negative cable. (4) Close the hood and check for proper operation. TRANSPONDER KEY DESCRIPTION The Sentry Key Immobilizer System (SKIS) uses a transponder chip that is integral to each ignition key (Fig. 1) to communicate with the Sentry Key Immobilizer Module (SKIM). Ignition keys are supplied with the vehicle when it is shipped from the factory. The transponder chip is undermolded within the head of the key. This undermold is hidden beneath an overmolded rubber cap. OPERATION Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKIM has a unique 9Secret Key9 code programmed into it by the manufacturer as well. When a Sentry Key is programmed into the memory of the SKIM, the SKIM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the 9Secret Key9 code from the SKIM. Once the Sentry Key learns the 9Secret Key9 code of the SKIM, it is also permanently programmed into the transponder’s memory. Therefore, blank keys for the SKIS must be programmed by the 8Q - 4 VEHICLE THEFT SECURITY RS TRANSPONDER KEY (Continued) STANDARD PROCEDURE - TRANSPONDER PROGRAMMING USING A DRB IIIT SCAN TOOL Fig. 1 TRANSPONDER KEY - TYPICAL 1 2 3 4 - MOLDED CAP TRANSPONDER MOLDED CAP REMOVED SENTRY KEY SKIM in addition to being cut to match the mechanical coding of the ignition lock cylinder. Refer to Electrical, Vehicle Theft Security, Transponder Key, Standard Procedure - Transponder Programming. The Sentry Key’s transponder is within the range of the SKIM’s transceiver antenna ring when it is inserted into the ignition lock cylinder. When the ignition switch is turned to the ON position, the SKIM communicates with the Sentry Key via a radio frequency (RF) signal. The SKIM determines if a valid key is present based on the information it receives from the Sentry Key. If a valid key is detected, that fact is communicated to the PCM via the PCI bus and the vehicle is allowed to continue running. If an invalid key is received by the PCM or no status at all is communicated, the vehicle will stall after two (2) seconds of running. The indicator light will be flashing at this point. The Sentry Key’s transponder can not be repaired. If it is faulty or damaged, it must be replaced. Common communication problems: • Two transponder keys too close together. • Speed Pass too close to transponder key. Solid indicator that there is a system failure. • Loss of PCM communication. • Failed antenna circuit. All Sentry Keys included with the vehicle are preprogrammed to work with the Sentry Key Immobilizer System (SKIS) when it is shipped from the factory. The Sentry Key Immobilizer Module (SKIM) can be programmed to recognize up to a total of eight Sentry Keys. When programming a blank Sentry Key transponder, the key must first be cut to match the ignition lock cylinder of the vehicle for which it will be used. The vehicle’s four digit PIN code will be required to complete this task since you will need it to enter the Secured Access Mode in the SKIM. The following steps must be completed using a DRB IIIt scan tool: (1) Insert the blank key into the ignition and turn it to the RUN position. (2) Using a DRB IIIt scan tool, select 9Theft Alarm,9 9SKIM,9 9Miscellaneous,9 and then 9Program New Key.9 (3) Enter the four digit PIN code using the DRB IIIt scan tool. When programming is completed, the SKIM will exit Secured Access Mode and the DRB IIIt scan tool will display the results of your attempt to program the key. One of five distinct results may be displayed. All five are listed below: • (Programming Successful( is displayed if the Sentry Key programming is successful. • (Learned Key in Ignition( is displayed if the key in the ignition has already been programmed into that vehicle’s SKIM. • (Eight Keys Already Learned (At The Maximum) Programming Not Done( is displayed if eight keys have already been programmed into the SKIM. In this case, if a new key needs to be added due to a lost or defective key, the 9Erase All Keys9 command (which requires entering the Secured Access Mode) has to be performed. Following the 9Erase All Keys9 command, all keys that will be used to operate the vehicle MUST be reprogrammed to the SKIM. • (Programming Not Attempted( is displayed after an 9Erase All Keys9 function is executed. • (Programming Key Failed( is displayed if further diagnosis is required. To learn additional keys, turn the ignition OFF, remove the learned key, insert the next new blank key, and repeat the steps from the beginning. “CUSTOMER LEARN” MODE This feature is only available on domestic vehicles or those which have a U.S. country code designator. This procedure requires access to at least two valid Sentry Keys. If two valid Sentry Keys are not avail- VEHICLE THEFT SECURITY RS 8Q - 5 TRANSPONDER KEY (Continued) able, Sentry Key programming will require the use of a DRB IIIt scan tool. The steps required to program Sentry Keys with two valid Sentry Keys follows: (1) Obtain the blank Sentry Key(s) that need to be programmed. Cut the keys to match the ignition lock cylinder mechanical key codes. (2) Insert one of the two valid Sentry Keys into the ignition switch and turn the ignition switch to the ON position. (3) After the ignition switch has been in the ON position for longer than three seconds, but no more than fifteen seconds, cycle the ignition switch back to the OFF position. Replace the first valid Sentry Key in the ignition lock cylinder with the second valid Sentry Key and turn the ignition switch back to the ON position. The second valid Sentry Key must be inserted within 15 seconds of removing the first valid Sentry key. (4) About ten seconds after the completion of Step 3, the indicator light will start to flash and a single audible chime tone will sound to indicate that the system has entered the 9Customer Learn9 programming mode. (5) Within sixty seconds of entering the 9Customer Learn9 programming mode, turn the ignition switch to the OFF position, replace the valid Sentry Key with a blank Sentry Key transponder, and turn the ignition switch back to the ON position. (6) About ten seconds after the completion of Step 5, a single audible chime tone will sound and the indicator light will stop flashing and stay on solid for three seconds and then turn off to indicate that the blank Sentry Key has been successfully programmed. The SKIS will immediately exit the 9Customer Learn9 programming mode and the vehicle may be started using the newly programmed Sentry Key. These steps must be completed in their entirety for each additional Sentry Key to be programmed. If any of the above steps are not completed in the given sequence, or within the allotted time, the SKIS will exit the 9Customer Learn9 programming mode and the programming will be unsuccessful. The SKIS will also automatically exit the 9Customer Learn9 programming mode if: • It sees a non-blank Sentry Key when it should see a blank. • If it has already programmed eight (8) valid Sentry Keys. • If the ignition switch is turned to the OFF position for more than about fifty (50) seconds. NOTE: If you attempt to start the vehicle while in “Customer Learn” mode (LED flashing), the vehicle will behave as though an invalid key is being used (i.e. the engine will stall after two (2) seconds of running). No faults will be logged. NOTE: Once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. VTSS/SKIS INDICATOR LAMP DESCRIPTION The Sentry Key Immobilizer System (SKIS) uses an indicator light to convey information on the status of the system to the customer. This light is shared with the Vehicle Theft Security System (VTSS). The light is located in the Message Center. The indicator light is controlled by the Body Control Module (BCM) based upon messages it receives from the Sentry Key Immobilizer Module (SKIM) on the PCI bus. OPERATION The BCM performs a four second bulb check, regardless of SKIM messages. After the bulb check, the lamp is controlled according to SKIM messages. Then, the SKIM sends messages to the BCM to operate the light based upon the results of the SKIS self tests. The light may be actuated in two possible ways, flashing or on solid. If the light comes on and stays on solid after a power-up test, this indicates that the SKIM has detected a system malfunction. If the SKIM detects an invalid key when the ignition switch is moved to the ON position, it sends a message on the PCI bus to the BCM, to flash the light. The SKIM can also send a message to flash the light and generate a single audible chime at the same time. These two events occurring simultaneously indicate that the SKIS has been placed into the 9Customer Learn9 mode. Refer to Electrical, Vehicle Theft Security, Transponder Key, Standard Procedure Transponder Programming for more information on the 9Customer Learn9 mode. If the light comes on and stays on after the power-up test, diagnosis of the SKIS should be performed using a DRB IIIt scan tool and the appropriate Body Diagnostic Procedures manual. The light is not a serviceable component. COOLING RS 7-1 COOLING TABLE OF CONTENTS page COOLING DESCRIPTION DESCRIPTION - COOLING SYSTEM . DESCRIPTION - HOSE CLAMPS . . . . OPERATION OPERATION - COOLING SYSTEM .. OPERATION - HOSE CLAMPS . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST . . . . . . . . . . . . . DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK . . . . . . . . . . DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION . . . . . . . . . . . . . DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE - COOLING SYSTEM DRAINING . . . . . . . . . . . . . .......1 .......1 .......2 .......2 .......2 .......3 .......4 page STANDARD PROCEDURE - COOLING SYSTEM FILLING . . . . . . . . . . . . . . . . . . . . . . 4 STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT . . . . . . . . . . . . . . . . . 4 STANDARD PROCEDURE - COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIFICATIONS COOLING SYSTEM CAPACITY . . . . . . . . . . . . 6 ACCESSORY DRIVE BELT TENSION . . . . . . . 6 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7 ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . . 8 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 38 .......4 .......4 COOLING DESCRIPTION DESCRIPTION - COOLING SYSTEM The cooling system components consist of a radiator, electric fan motors, shroud, pressure cap, thermostat, transmission oil cooler, water pump, hoses, clamps, coolant, and a coolant reserve system to complete the circuit. DESCRIPTION - HOSE CLAMPS The cooling system uses spring type hose clamps. If a spring type clamp replacement is necessary, replace with the original Mopart equipment spring type clamp. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter (Fig. 1). Fig. 1 Spring Clamp Size Location 1 - SPRING CLAMP SIZE LOCATION 7-2 COOLING RS COOLING (Continued) OPERATION - HOSE CLAMPS OPERATION OPERATION - COOLING SYSTEM The engine cooling systems primary purpose is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions. It also provides hot water (coolant) for heater performance and cooling for automatic transmission oil. It does this by transferring heat from engine metal to coolant, moving this heated coolant to the radiator, and then transferring this heat to the ambient air. • When engine is cold: thermostat is closed, cooling system has no flow through the radiator. The coolant bypass flows through the engine only. • When engine is warm: thermostat is open, cooling system has bypass flow and coolant flow through radiator. Coolant flow circuits for the 2.4L and 3.3/3.8L engines are shown in (Fig. 2). The spring type hose clamp applies constant tension on a hose connection. To remove a spring type hose clamp, use Special Tool 6094 or equivalent, constant tension clamp pliers (Fig. 3) to compress the hose clamp. DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST WARNING: THE WARNING WORDS “DO NOT OPEN HOT” ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. Fig. 2 Cooling System Flow 1 2 3 4 5 - HEATER - REAR (3.3/3.8L OPTIONAL EQUIPMENT) HEATER - FRONT ENGINE THERMOSTAT ENGINE OIL COOLER (3.3/3.8L OPTIONAL EQUIPMENT) 6 - WATER PUMP 7 - RADIATOR 8 - COOLANT RECOVERY/RESERVE CONTAINER 9 - COOLANT FLOW - PRESSURE CAP VACUUM 10 - COOLANT FLOW - PRESSURE CAP RELIEF COOLING RS 7-3 COOLING (Continued) If there are no external leaks, after the gauge dial shows a drop in pressure, detach the tester. Start engine and run until the thermostat opens, allowing the coolant to expand. Reattach the cooling system tester. If the needle on the dial fluctuates it indicates a combustion leak, usually a head gasket leak. WARNING: WITH TOOL IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). Fig. 3 Hose Clamp Tool 1 - HOSE CLAMP TOOL 6094 2 - HOSE CLAMP With engine not running, remove radiator pressure cap and wipe the radiator filler neck sealing seat clean. The radiator should be full. Attach the Cooling System Tester 7700 or equivalent to the radiator, as shown in (Fig. 4) and apply 104 kPa (15 psi) pressure. If the pressure drops more than 13.8 kPa (2 psi) in 2 minutes, inspect all points for external leaks. All radiator and heater hoses should be shaken while at 104 kPa (15 psi), since some leaks occur only while driving due to engine movement. If the needle on the dial does not fluctuate, raise the engine rpm a few times. If an abnormal amount of coolant or steam emits from the tailpipe, it may indicate a coolant leak caused by a faulty head gasket, cracked engine block, or cracked cylinder head. There may be internal leaks that can be determined by removing the oil dipstick. If water globules appear intermixed with the oil it will indicate an internal leak in the engine. If there is an internal leak, the engine must be disassembled for repair. DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK To determine whether coolant is flowing through the cooling system, use one of the following procedures: PREFERRED METHOD WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP OR ANY HOSE WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. • Remove pressure cap when engine is cold. Remove small amount of coolant. Idle engine until thermostat opens. You should observe coolant flow while looking down the filler neck. Once flow is detected install the pressure cap. Replace removed coolant into coolant recovery container. ALTERNATIVE METHOD • If engine is cold, idle engine until normal operating temperature is reached. Feel the upper radiator hose. If it is hot, coolant is circulating. Fig. 4 Pressure Testing 7-4 COOLING RS COOLING (Continued) DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION Low coolant level in a cross flow radiator will equalize in both tanks with engine off. With engine at running and at operating temperature, the high pressure inlet tank runs full and the low pressure outlet tank drops, resulting in cooling system aeration. Aeration will draw air into the water pump resulting in the following: • High reading shown on the temperature gauge. • Loss of coolant flow through the heater core. • Corrosion in the cooling system. • Water pump seal may run dry, increasing the risk of premature seal failure. • Combustion gas leaks into the coolant can also cause the above problems. DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION Air can only be removed from the system by gathering under the pressure cap. On the next heat up it will be pushed past the pressure cap into the coolant recovery bottle by thermal expansion of the coolant. It then escapes to the atmosphere in the coolant recovery bottle and is replaced with coolant on cool down. To effectively deaerate the system, multiple thermal cycles of the system may be required. NOTE: Deaeration does not occur at engine idle— higher engine speeds are required. Normal driving will deaerate cooling system. STANDARD PROCEDURE STANDARD PROCEDURE - COOLING SYSTEM DRAINING WARNING: DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN THE SYSTEM IS HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR. (1) Without removing radiator pressure cap and with system not under pressure, open the draincock. The draincock is located on the lower left side of radiator (Fig. 5). (2) After the coolant recovery/reserve container is empty, then remove coolant pressure cap (Fig. 6). (3) Remove the cylinder block drain plug(s). Fig. 5 Draincock Location 1 - LEFT SIDE FRAME RAIL 2 - DRAINCOCK STANDARD PROCEDURE - COOLING SYSTEM FILLING Remove radiator pressure cap (Fig. 6) and fill system, using a 50/50 mix of Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula and distilled water. Continue filling system until full. Be careful not to spill coolant on drive belts or the generator. Fill coolant recovery/reserve container (Fig. 6) to at least the MAX mark with 50/50 solution. It may be necessary to add coolant to the recovery/reserve container after three or four warm up/cool down cycles to maintain coolant level between the MAX and MIN mark. This will allow trapped air to be removed from the system. STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT The radiator cap should not be removed. When additional coolant is needed to maintain this level, it should be added to the coolant recovery/reserve container (Fig. 6). Use only 50/50 mix of ethylene glycol type antifreeze and distilled water. For the recommeded antifreeze/coolant type (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES DESCRIPTION). CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. For the recommeded antifreeze/coolant type (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES DESCRIPTION). COOLING RS COOLING (Continued) Fig. 6 Cooling System Service Locations 1 - COOLANT RECOVERY CONTAINER 2 - ENGINE OIL FILL CAP 3 - ENGINE OIL LEVEL DIPSTICK 4 - RADIATOR PRESSURE CAP STANDARD PROCEDURE - COOLANT LEVEL CHECK NOTE: Do not remove radiator cap for routine coolant level inspections. The coolant reserve system provides a quick visual method for determining the coolant level without removing the radiator cap. With the engine cold and not running, simply observe the level of the coolant in the recovery/reserve container (Fig. 7). The coolant level should be between the MIN and MAX marks. Fig. 7 Coolant Recovery Container 7-5 7-6 COOLING RS COOLING (Continued) TORQUE SPECIFICATIONS COOLING SYSTEM CAPACITY Engine DESCRIPTION Coolant Capacity* 2.4L 10.7 L (11.4 qts.) 3.3/3.8L (without rear heater) 12.6 L (13.4 qts.) 3.3/3.8L (with rear heater) 15.4 L (16.3 qts.) *Includes Heater and Coolant Recovery System ACCESSORY DRIVE BELT TENSION ACCESSORY DRIVE BELT 28 Ft. In. Lbs. Lbs. — 250 Engine Coolant Temperature Sensor (2.4 & 3.3/3.8L) 7 — 60 Generator & A/C Compressor Drive Belt Tensioner Assembly (2.4L)— Bolt 54 40 — (2.4 & 3.3/3.8L)—Bolts 28 — 250 (2.4 & 3.3/3.8L)—Bolts 12 — 105 Water Pump Inlet Tube (2.4L)— Bolts 12 — 105 Water Pump Inlet Tube (3.3/3.8L)— Bolts 28 — 250 Water Pump Pulley (3.3/3.8L)— Bolts 28 — 250 Radiator to A/C Condenser— Screws 5 — 45 Radiator Fan—Screws 5 — 45 Radiator Mounting (Upper Bracket)—Nuts 12 — 105 Coolant Outlet Connector/ Thermostat Housing TENSION Water Pump 2.4L ENGINE Air Conditioning Compressor/ Generator Power Steering Accessory Drive Belt Tensioner Assembly (3.3/3.8L)—Bolt N·m Dynamic Tensioner 534 - 756 N New Belt (120 - 170 lbs.) 356 - 534 N Used Belt* (80 - 120 lbs) 183 - 218 Hz 150 - 183 Hz *Belt is considered used after 15 minutes of run-in time 3.3/3.8L ENGINES Air Conditioning Compressor Generator/Water Pump/Power Steering Dynamic Tensioner COOLING RS COOLING (Continued) SPECIAL TOOLS COOLING SYSTEM DRB IIIT with PEP Module – OT-CH6010A Hose Clamp Pliers 6094 Belt Tension Gauge Adapter 8371 Hose Clamp Pliers 8495A Belt Tension Gauge 7198A Cooling System Tester 7700 Cooler Flusher 6906-C Coolant Refractometer 8286 7-7 7-8 ACCESSORY DRIVE RS ACCESSORY DRIVE TABLE OF CONTENTS page page BELT TENSIONER - 2.4L REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 BELT TENSIONER - 3.3/3.8L REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DRIVE BELTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DRIVE BELTS - 2.4L STANDARD PROCEDURE - CHECKING POWER STEERING BELT TENSION . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 12 DRIVE BELTS - 3.3/3.8L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 BELT TENSIONER - 2.4L INSTALLATION REMOVAL (1) Raise vehicle on hoist. (2) Remove the drive belt shield. (3) Remove the generator/A/C drive belt. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL) (4) Remove the belt tensioner (Fig. 1). (1) Install belt tensioner and bolt (Fig. 1). Tighten bolt to 54 N·m (40 ft. lbs.). (2) Install generator/A/C compressor drive belt. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) (3) Install splash shield. (4) Lower the vehicle. BELT TENSIONER - 3.3/3.8L REMOVAL (1) Raise vehicle on hoist. (2) Remove the drive belt shield. (3) Remove the drive belt. (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) (4) Remove the belt tensioner (Fig. 2). INSTALLATION Fig. 1 Belt Tensioner - 2.4L 1 - BELT TENSIONER 2 - GENERATOR BRACKET 3 - BOLT (1) Install the belt tensioner and bolt (Fig. 2). Tighten bolt to 28 N·m (250 in. lbs.). (2) Install the drive belt. (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) (3) Install the drive belt shield. (4) Lower the vehicle. ACCESSORY DRIVE RS 7-9 BELT TENSIONER - 3.3/3.8L (Continued) DRIVE BELTS DESCRIPTION The drive belts are a Poly-V type belt. Belt widths vary depending on the various engine and accessory packages. Satisfactory performance of these belts depends on belt condition and proper belt tension. OPERATION The accessory drive belts form the link between the engine crankshaft and the engine driven accessories. Fig. 2 BELT TENSIONER - 3.3/3.8L 1 - BELT TENSIONER 2 - BOLT DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT CONDITION INSUFFICIENT ACCESSORY OUTPUT DUE TO BELT SLIPPAGE POSSIBLE CAUSES 1. Belt too loose CORRECTIONS 1. (a) Replace belt (auto-tensioned belts) (b) Adjust power steering belt tension (4 cyl. engine) BELT SQUEAL WHEN ACCELERATING ENGINE 2. Belt excessively glazed or worn 2. Replace and tighten as specified 1. Belts too loose 1. (a) Replace belt (auto-tensioned belts) (b) Adjust power steering belt tension (4 cyl. engine) BELT SQUEAK AT IDLE 2. Belt glazed 2. Replace belts 1. Belts too loose 1. (a) Replace belt (auto-tensioned belts) (b) Adjust power steering belt tension (4 cyl. engine) 2. Dirt or paint imbedded in belt 2. Replace belt 3. Non-uniform belt 3. Replace belt 4. Misaligned pulleys 4. Align accessories 5. Non-uniform groove or eccentric pulley 5. Replace pulley 7 - 10 ACCESSORY DRIVE RS DRIVE BELTS (Continued) CONDITION POSSIBLE CAUSES BELT ROLLED OVER IN GROOVE OR BELT JUMPS OFF CORRECTIONS 1. Broken cord in belt 1. Replace belt 2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned belts.) (b) Adjust power steering belt tension (4 cyl. engine) 3. Misaligned pulleys 3. Align accessories 4. Non-uniform groove or eccentric pulley 4. Replace pulley DRIVE BELTS - 2.4L STANDARD PROCEDURE - CHECKING POWER STEERING BELT TENSION WARNING: DO NOT CHECK BELT TENSION WITH ENGINE RUNNING. Accessory drive belt tension can be measured with Special Tool 8371 – Belt Tension Gauge Adapter, and the DRBIIIt using the following procedures: (1) Connect 8371 to the DRBIIIt following the instructions provided with tool. (2) Place end of microphone probe approximately 2.54 cm (1 in.) from belt at belt center span location shown in (Fig. 3). (3) Pluck the belt a minimum of 3 times. (Use your finger or other suitable tool) The frequency of the belt in hertz (Hz) will display on DRBIIIt screen. (4) Adjust belt to obtain proper frequency (tension). Refer to ACCESSORY DRIVE BELT TENSION CHART for belt tension specifications. ACCESSORY DRIVE BELT TENSION CHART 2.4L Accessory Drive Belt Belt Tension Air Conditioning Compressor/Generator Dynamic Tensioner New Power Steering Pump Used* 183 - 218 Hz 150 - 183 Hz *A belt is considered used after 15 minutes of run-in time. Fig. 3 Power Steering Belt - Center Span Location 1 - POWER STEERING BELT CENTER SPAN LOCATION WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK, AS DAMAGE TO TENSIONER AND/OR PERSONAL INJURY COULD RESULT. (3) Position a wrench on the belt tensioner lug (Fig. 4). (4) Release belt tension by rotating the tensioner clockwise (Fig. 4). (5) Remove belt. (1) Carefully return tensioner to its relaxed position. REMOVAL POWER STEERING PUMP GENERATOR AND AIR CONDITIONING BELT (1) From top of the vehicle, loosen locking nuts (D) and (F) (Fig. 5). (1) Raise vehicle on hoist. (2) Remove the drive belt shield (Fig. 8). ACCESSORY DRIVE RS 7 - 11 DRIVE BELTS - 2.4L (Continued) 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. INSPECTION Belt replacement under any or all of the following conditions is required: • Excessive wear • Frayed cords • Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 6). Fig. 4 A/C & GENERATOR BELT TENSION RELEASE 1 - BELT TENSIONER 2 - WRENCH NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. (2) From under the vehicle, loosen the pivot bolt (E). Loosen adjusting bolt (G) until belt can be removed. Fig. 6 Drive Belt Wear Pattern 1 - NORMAL CRACKS - BELT OK 2 - NOT NORMAL CRACKS - REPLACE BELT INSTALLATION GENERATOR AND AIR CONDITIONING BELT Fig. 5 Power Steering Pump 1 2 3 4 - REAR LOCKING NUT - ADJUSTING BOLT - PIVOT BOLT - FRONT LOCKING NUT (1) Install belt onto all pulleys except for the crankshaft (Fig. 7). (2) Rotate belt tensioner clockwise until belt can be installed onto the crankshaft pulley (Fig. 4). Slowly release belt tensioner. (3) Verify belt is properly routed and engaged on all pulleys (Fig. 7). (4) Install drive belt shield (Fig. 8) and lower vehicle. 7 - 12 ACCESSORY DRIVE RS DRIVE BELTS - 2.4L (Continued) DRIVE BELTS - 3.3/3.8L REMOVAL (1) Raise vehicle on hoist. (2) Remove the drive belt shield (Fig. 8). Fig. 7 Accessory Drive Belts - 2.4L 1 2 3 4 5 6 7 - POWER STEERING PUMP PULLEY - BELT TENSIONER - GENERATOR PULLEY - BELT - A/C AND GENERATOR - A/C COMPRESSOR PULLEY - CRANKSHAFT PULLEY - BELT - POWER STEERING POWER STEERING PUMP (1) Install belt over crankshaft and power steering pump pulleys (Fig. 7). (2) Apply an initial snug torque to fasteners (E) and (F) (Fig. 5). (3) Tighten adjusting bolt (G) until proper belt tension is obtained (Fig. 5). For belt tension check procedure, (Refer to 7 - COOLING/ACCESSORY DRIVE/ DRIVE BELTS - STANDARD PROCEDURE CHECKING POWER STEERING BELT TENSION). (4) Tighten locking nuts (D) and (F) to 54 N·m (40 ft. lbs.) (Fig. 5). (5) Tighten pivot bolt (E) to 54 N·m (40 ft. lbs.) (Fig. 5). Fig. 8 Accessory Drive Belt Shield 1 - ATTACHING SCREW 2 - ATTACHING SCREWS 3 - SPLASH SHIELD WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK, AS DAMAGE TO TENSIONER AND/OR PERSONAL INJURY COULD RESULT. (3) Position a wrench on the belt tensioner lug (Fig. 9). (4) Release belt tension by rotating the tensioner counterclockwise (Fig. 9). ADJUSTMENTS Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt tensioning should be performed with the aid of Special Tool 7198. Because of space limitations in the engine compartment, the use of this gauge may be restricted. Raise the vehicle on a hoist and the remove the splash shield to gain access to the drive belts, if necessary. Adjust belt tension for either a New or Used belt. For specifications, (Refer to 7 - COOLING/ACCESSORY DRIVE - SPECIFICATIONS). Fig. 9 DRIVE BELT TENSION RELEASE 1 - BLET TENSIONER LUG 2 - WRENCH ACCESSORY DRIVE RS 7 - 13 DRIVE BELTS - 3.3/3.8L (Continued) (5) Remove the drive belt (Fig. 11). (6) Carefully return tensioner to its relaxed position. INSTALLATION (1) Route and position the drive belt onto all pulleys, except for the crankshaft (Fig. 11). 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. INSPECTION Belt replacement under any or all of the following conditions is required: • Excessive wear • Frayed cords • Severe glazing Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 10). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. Fig. 11 ACCESSORY DRIVE BELT 1 2 3 4 5 6 7 8 - DRIVE BELT - POWER STEERING PUMP PULLEY - BELT TENIONER PULLEY - IDLER PULLEY - GENERATOR PULLEY - AIR CONDITIONING COMPRESSOR PULLEY - CRANKSHAFT PULLEY - WATER PUMP PULLEY (2) Rotate belt tensioner counterclockwise until belt can be installed onto the crankshaft pulley (Fig. 9). Slowly release belt tensioner. (3) Verify belt is properly routed and engaged on all pulleys. (4) Install drive belt shield (Fig. 8) and lower vehicle. Fig. 10 Drive Belt Wear Pattern 1 - NORMAL CRACKS - BELT OK 2 - NOT NORMAL CRACKS - REPLACE BELT 7 - 14 ENGINE RS ENGINE TABLE OF CONTENTS page ENGINE DIAGNOSIS AND TESTING - ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ........................ COOLANT DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING . . . . . . . . . . . STANDARD PROCEDURE - COOLANT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT RECOVERY CONTAINER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - COOLANT RECOVERY SYSTEM ................ REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ENGINE BLOCK HEATER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER TESTING . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT TEMPERATURE SENSOR 2.4L DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT TEMPERATURE SENSOR 3.3/3.8L DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT THERMOSTAT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT . . . . . . . . . . . . . ENGINE COOLANT THERMOSTAT - 2.4L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT THERMOSTAT - 3.3/3.8L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . RADIATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . 19 . . 19 . . 19 . . 20 . . 20 . . 20 . . 20 . . 20 . . 20 . . 21 . . 21 . . 21 . . 21 . . 21 . . 21 . . 21 . . 21 . . 22 . . 22 . . 22 . . 23 . . 23 . . 23 . . 23 . . 23 . . 24 . . 24 . . 25 . . 25 page REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . RADIATOR DRAINCOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . RADIATOR PRESSURE CAP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING . . . . DIAGNOSIS AND TESTING - RADIATOR CAP TO FILLER NECK SEAL . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... RADIATOR FAN DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . RADIATOR FAN RELAY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . WATER PUMP - 2.4L DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . WATER PUMP - 3.3/3.8L DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . WATER PUMP INLET TUBE - 2.4L DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . WATER PUMP INLET TUBE - 3.3/3.8L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . 26 . . . 27 . . . 27 . . . 27 . . . 27 . . . 28 . . . 28 . . . 29 . . . 29 . . . 29 . . . 29 . . . 30 . . . 30 . . . 30 . . . . . . . . . 31 . 31 . 31 . 31 . . . . . . . . . . . . . 32 . 32 . 32 . 32 . 32 . 32 . . . . . . . . . . . . . 34 . 34 . 34 . 35 . 35 . 35 . . . 36 . . . 36 . . . 36 . . . 36 . . . 36 ENGINE RS 7 - 15 VISUAL INSPECTION ENGINE DIAGNOSIS AND TESTING - ENGINE COOLING SYSTEM Establish what driving condition caused the cooling system complaint. The problem may be caused by an abnormal load on the system such as the following: prolonged idle, very high ambient temperature, slight tail wind at idle, slow traffic speed, traffic jam, high speed, steep grade. DRIVING TECHNIQUES To avoid overheating the cooling system: (1) Idle with A/C off when temperature gauge is at end of normal range. (2) Do not increase engine speed for more air flow and coolant flow because the electric motor fan systems are not responsive to engine RPM. The added cooling from higher coolant flow rate is more than offset by increased heat rejection (engine heat added to coolant). TRAILER TOWING If the cooling system problem is not caused by a driving condition, perform a visual inspection to determine if there was a recent service or accident repair, including the following: • Loose/damaged water pump drive belt • Incorrect cooling system refilling (trapped air or low level) • Brakes possibly dragging • Damaged hoses • Loose/damaged hose clamps • Damaged/incorrect engine thermostat • Damaged cooling fan motor, fan blade and fan shroud • Damaged head gasket • Damaged water pump • Damaged radiator • Damaged coolant recovery system • Damaged heater core • Open/shorted electrical circuits If the visual inspection reveals none of the above as cause for a cooling system complaint, refer to the following diagnostic charts. Consult the owner’s manual under Trailer Towing and do not exceed specified limits. COOLING SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION PRESSURE CAP IS BLOWING OFF STEAM AND/OR COOLANT. TEMPERATURE GAUGE READING MAY BE ABOVE NORMAL BUT NOT HIGH. COOLANT LEVEL MAY BE HIGH IN COOLANT RESERVE/ OVERFLOW TANK. 1. Pressure relief valve in radiator cap is defective, or was not properly seated. 1. Check condition of radiator cap and cap seal. (Refer to 7 COOLING/ENGINE/RADIATOR PRESSURE CAP - DIAGNOSIS AND TESTING) Replace cap as necessary. 2. Incorrect cap was installed. 2. Replace cap as necessary. 3. Incorrect coolant mixture. 3. Check concentration level of the coolant. (Refer to 7 - COOLING/ ENGINE/COOLANT - DIAGNOSIS AND TESTING) Adjust the ethylene glycol-to-water ratio as required. 1. Coolant leaks in radiator, cooling system hoses, water pump or engine. 1. Pressure test and repair as necessary. (Refer to 7 - COOLING DIAGNOSIS AND TESTING) COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF. GAUGE IS READING HIGH OR HOT. 7 - 16 ENGINE RS ENGINE (Continued) CONDITION POSSIBLE CAUSES CORRECTION DETONATION OR PRE-IGNITION (NOT CAUSED BY IGNITION SYSTEM). GAUGE MAY NOT BE READING HIGH. 1. Engine overheating. 1. Check reason for overheating and repair as necessary. 2. Freeze point of coolant not correct. Mixture too concentrated or too diluted. 2. Check concentration level of the coolant. (Refer to 7 - COOLING/ ENGINE/COOLANT - DIAGNOSIS AND TESTING) Adjust the ethylene glycol-to-water ratio as required. 3. Incorrect cooling system pressure cap. 3. Install correct pressure cap. 1. Vacuum created in cooling system on engine cool-down is not being relieved through coolant recovery system. 1. (a) Pressure cap relief valve stuck. (Refer to 7 - COOLING/ ENGINE/RADIATOR PRESSURE CAP - DIAGNOSIS AND TESTING) Replace as necessary. HOSE(S) COLLAPSE AS ENGINE COOLS DOWN. (b) Hose between the radiator and overflow container is plugged or pinched. Clean and repair as necessary. (c) Vent at coolant reserve/overflow container is plugged. Clean vent and repair as necessary. (d) Reserve/overflow container is internally blocked. Clean and repair as necessary. INADEQUATE AIR CONDITIONER PERFORMANCE (COOLING SYSTEM SUSPECTED). INADEQUATE HEATER PERFORMANCE. 1. Radiator and/or A/C condenser is restricted, obstructed, or dirty (insects, leaves, etc.). 1. Remove restriction and/or clean as necessary. 2. Electrical radiator fan not operating when A/C is operated. 2. For test procedure (Refer to appropriate Diagnostic Information). Repair as necessary. 3. Engine is overheating (heat may be transferred from radiator to A/C condenser). High underhood temperatures due to engine overheating may also transfer heat to A/C components. 3. Correct overheating condition. 4. All models are equipped with air seals at the radiator and/or A/C condenser. If these seals are missing or damaged, not enough air flow will be pulled through the radiator and A/C condenser. 4. Check for missing or damaged air seals and repair as necessary. 1. Check for a Diagnostic trouble code (DTC). 1. For procedures, (Refer to appropriate Diagnostic Information). Repair as necessary. 2. Coolant level low. 2. (Refer to 7 - COOLING STANDARD PROCEDURE) Repair as necessary. ENGINE RS 7 - 17 ENGINE (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Obstructions in heater hose fitting at engine or at heater core. 3. Remove heater hoses at both ends and check for obstructions. Repair as necessary. 4. Heater hose kinked. 4. Locate kinked area and repair as necessary. 5. Water pump is not pumping coolant to heater core. 5. When the engine is fully warmed up, both heater hoses should be hot to the touch. If only one of the hoses is hot, the water pump may not be operating correctly. Replace components as necessary. 6. Air trapped in heater core. 6. (Refer to 7 - COOLING DIAGNOSIS AND TESTING COOLING SYSTEM DEAERATION) 1. Various heat shields are used at certain driveline components. One or more of these shields may be missing. 1. Locate missing shields and replace or repair as necessary. 2. Temperature gauge reading above the normal range. 2. Refer to Gauge Is Reading High in Temperature Gauge Indicatication Diagnosis Chart. 3. Radiator fan operating incorrectly. 3. (Refer to 7 - COOLING/ENGINE/ RADIATOR FAN - OPERATION) Repair as necessary. 4. Undercoating been applied to an unnecessary component. 4. Clean undercoating as necessary. 5. Engine may be running rich, causing the catalytic converter to overheat 5. (Refer to Appropriate Diagnostic Information) Repair as necessary. POOR DRIVEABILITY (THERMOSTAT POSSIBLY STUCK OPEN). GAUGE MAY BE READING LOW. 1. The engine thermostat must be operating correctly for proper driveability, clean vehicle emissions, and the prevention of sludge buildup in the engine oil. Check for a diagnostic trouble code. 1. (Refer to Appropriate Diagnostic Information) Replace thermostat, if necessary. STEAM IS COMING FROM FRONT OF VEHICLE NEAR GRILL AREA WHEN WEATHER IS WET, ENGINE WARMED UP AND RUNNING WITH VEHICLE STATIONARY, OR JUST SHUT OFF. TEMPERATURE GAUGE IS NORMAL. 1. During wet weather, moisture (snow, ice, rain, or condensation) on the radiator will evaporate when the thermostat opens. The thermostat opening allows heated coolant into the radiator. When the moisture contacts the hot radiator, steam may be emitted. This usually occurs in cold weather with no fan or air flow to blow it away. 1. Occasional steam emitting from this area is normal. No repair is necessary. HEAT ODOR 7 - 18 ENGINE RS ENGINE (Continued) CONDITION POSSIBLE CAUSES CORRECTION COOLANT COLOR 1. Coolant color is not necessarily an indication of adequate corrosion or temperature protection. Do not rely on coolant color for determining condition of coolant. 1. Check the freeze point of the coolant. (Refer to 7 - COOLING/ ENGINE/COOLANT - DIAGNOSIS AND TESTING) Adjust the ethylene glycol-to-water ratio as necessary. COOLANT LEVEL CHANGES IN COOLANT BOTTLE. TEMPERATURE GAUGE IS IN NORMAL RANGE. 1. Level changes are to be expected as coolant volume fluctuates with engine temperature. The coolant level will also drop as the system removes air from a recent filling. 1. A normal condition. No repair is necessary. Refer to (Fig. 1) when using the TEMPERATURE GAUGE INDICATION DIAGNOSIS CHART. TEMPERATURE GAUGE INDICATION DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READING IS INCONSISTENT (FLUCTUATES, CYCLES OR IS ERRATIC). 1. Normal reaction to fan and/or thermostat cycle (Fig. 1 ), Examples B and C. During cold weather operation with the heater blower in the high position, the gauge reading may drop slightly (Fig. 1 ), Example D. Fluctuation is also influenced by outside temperature and heavy loads (Fig. 1 ), Example E. 1. A normal condition. No correction is necessary. 2. Gauge reading rises when vehicle is brought to a stop after heavy use (engine still running) (Fig. 1 ), Example F. 2. A normal condition. No correction is necessary. Gauge reading should return to normal range (Fig. 1 ), Example A, after vehicle is driven. 3. Gauge reading high after restarting a warmed-up (hot) engine. 3. A normal condition. No correction is necessary. The gauge should return to normal range (Fig. 1 ), Example A, after a few minutes of engine operation. 4. Temperature gauge or engine coolant temperature sensor defective or shorted. Also, corroded or loose wiring in the electrical circuit. 4. Check operation of gauge or engine coolant temperature sensor and repair, if necessary. ENGINE RS 7 - 19 ENGINE (Continued) Fig. 1 Temperature Gauge Indications CLEANING Drain cooling system and refill with clean water. Refer to drain and fill procedures in this section. Run engine with radiator cap installed until upper radiator hose is hot. Stop engine and drain water from system. If water is dirty; fill, run, and drain system again, until water runs clear. Refill cooling system with a 50/50 mixture of the recommended ethylene glycol and distilled water (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). INSPECTION After performing a cleaning/flush procedure, inspect all hoses, clamps and connections for deterioration and leaks. Inspect radiator and heater core for leaks. COOLANT DIAGNOSIS AND 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 7 - 20 ENGINE RS COOLANT (Continued) higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer (Special Tool 8286)(Refer to 7 COOLING - SPECIAL TOOLS) 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. and the coolant level in the container is at or above the MIN mark, there is an air leak in the coolant recovery system. (3) Check hose and hose connections to the container, radiator filler neck or the pressure cap seal to the radiator filler neck for leaks. REMOVAL (1) (2) (3) (4) (5) 2). (6) Raise the vehicle on hoist. Remove the lower attaching screws (Fig. 2). Lower the vehicle. Remove the upper attaching screw (Fig. 2). Disconnect recovery hose from container (Fig. Remove the recovery container. STANDARD PROCEDURE - COOLANT SERVICE For engine coolant recommended service schedule, (Refer to LUBRICATION & MAINTENANCE/MAINTENANCE SCHEDULES - DESCRIPTION). COOLANT RECOVERY CONTAINER DESCRIPTION The coolant recovery/reserve system cotainer is mounted in the engine compartment (Fig. 2). The container is made of plastic. OPERATION The coolant recovery system works with the radiator pressure cap to use thermal expansion and contraction of the coolant to keep the coolant free of trapped air. Provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure without removing the radiator pressure cap. It also provides some reserve coolant to cover deaeration, evaporation, or boiling losses. DIAGNOSIS AND TESTING - COOLANT RECOVERY SYSTEM The cooling system is closed and designed to maintain coolant level to the top of the radiator. (1) With the engine off and cooling system not under pressure, drain several ounces of coolant from the radiator draincock while observing the coolant recovery container. Coolant level in the container should drop. (2) Remove the radiator pressure cap. The coolant level should be full to the top radiator neck. If not, Fig. 2 Coolant Recovery Container 1 2 3 4 5 6 - UPPER BOLT ATTACHING TO BATTERY TRAY COOLANT RECOVERY CONTAINER UPPER BOLT HOSE LOWER BOLT (QTY. 2) LEFT SIDE FRAME RAIL INSTALLATION (1) Connect the recovery hose to container (Fig. 2). (2) Position the recovery container on the frame rail (Fig. 2). (3) Install the upper attaching screw and tighten to 7 N·m (60 in. lbs.) (Fig. 2). (4) Raise the vehicle on hoist. (5) Install the lower attaching screws and tighten to 8.5 N·m (75 in. lbs.) (Fig. 2). (6) Lower the vehicle. (7) Add coolant to container as necessary. (Refer to 7 - COOLING - STANDARD PROCEDURE) ENGINE RS ENGINE BLOCK HEATER DESCRIPTION The engine block heater is available as an optional accessory on all models. The heater is operated by ordinary house current (110 Volt A.C.) through a power cord located behind the radiator grille. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant. OPERATION The block heater element is submerged in the cooling system’s coolant. When electrical power (110 volt A.C.) is applied to the element, it creates heat. This heat is transferred to the engine coolant. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. 7 - 21 ENGINE COOLANT TEMPERATURE SENSOR - 2.4L DESCRIPTION The engine coolant temperature sensor threads into the top of the thermostat housing (Fig. 3). New sensors have sealant applied to the threads. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. (1) Drain the cooling system below thermostat level. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Disconnect coolant temperature sensor electrical connector. (3) Remove coolant temperature sensor (Fig. 3). DIAGNOSIS AND TESTING - 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 110volt test light; test heater element continuity with an ohmmeter or 12-volt test light. REMOVAL (1) Drain coolant from radiator and cylinder block. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Disconnect the power cord plug from heater. (3) Loosen screw in center of heater. Remove the heater assembly. INSTALLATION (1) Clean block core hole and heater seat. (2) Insert heater assembly with element loop positioned upward. (3) With heater seated, tighten center screw securely to assure a positive seal. (4) Install power cord plug to heater. (5) Fill cooling system with coolant to the proper level. (Refer to 7 - COOLING - STANDARD PROCEDURE) Fig. 3 Engine Coolant Temperature Sensor - 2.4L 1 - MAP SENSOR 2 - COOLANT TEMPERATURE SENSOR INSTALLATION (1) Install coolant temperature sensor (Fig. 3). Tighten sensor to 7 N·m (60 in. lbs.). (2) Connect electrical connector to sensor. (3) Fill cooling system. (Refer to 7 - COOLING STANDARD PROCEDURE) 7 - 22 ENGINE ENGINE COOLANT TEMPERATURE SENSOR 3.3/3.8L RS (3) Remove ignition coil and bracket (Fig. 5). DESCRIPTION The engine coolant temperature sensor threads into a coolant passage on lower intake manifold near the thermostat (Fig. 6). New sensors have sealant applied to the threads. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. (1) Drain cooling system below engine coolant temperature sensor level. (Refer to 7 - COOLING STANDARD PROCEDURE) (2) Remove power steering reservoir and relocate (Fig. 4). Do not disconnect hoses. Fig. 5 Fuel Rail, Ignition Coil and Bracket 1 - FUEL RAIL 2 - BOLT - FUEL RAIL 3 - NUT - IGNITION COIL 4 - BOLT - IGNITION COIL 5 - IGNITION COIL 6 - BRACKET - IGNITION COIL 7 - STUD - IGNITION COIL 8 - SEPARATOR - SPARK PLUG CABLE 9 - BRACKET - SPARK PLUG CABLE SEPARATOR 10 - BOLT - SEPARATOR BRACKET 11 - BRACKET - SPARK PLUG CABLE SEPARATOR (4) Disconnect coolant sensor electrical connector (Fig. 6). (5) Remove coolant sensor (Fig. 6). INSTALLATION Fig. 4 Power Steering Fluid Reservoir 1 - POWER STEERING RESERVOIR 2 - BOLT - RESERVOIR TO MANIFOLD 3 - NUT - RESERVOIR TO COIL BRACKET (1) Install engine coolant temperature sensor (Fig. 6). Tighten sensor to 7 N·m (60 in. lbs.). (2) Connect electrical connector to sensor (Fig. 6). (3) Install ignition coil bracket (Fig. 5). (4) Install ignition coil (Fig. 5). (5) Install power steering reservoir (Fig. 4). ENGINE RS 7 - 23 ENGINE COOLANT TEMPERATURE SENSOR - 3.3/3.8L (Continued) reaches a predetermined temperature, the wax expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT Fig. 6 Engine Coolant Temperature Sensor 1 - ENGINE COOLANT TEMPERATURE SENSOR 2 - CONNECTOR - ENGINE COOLANT SENSOR 3 - FITTING - HEATER SUPPLY (6) Fill cooling system. (Refer to 7 - COOLING STANDARD PROCEDURE) ENGINE COOLANT THERMOSTAT DESCRIPTION The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. The thermostat is mounted in a housing on the coolant outlet of the engine (Fig. 8) or (Fig. 10). OPERATION The engine cooling thermostat is a wax pellet driven, reverse poppet choke type. The thermostat is designed to provide the fastest warm up possible by preventing leakage through it and to guarantee a minimum engine operating temperature of 88 to 93°C (192 to 199°F). The thermostat also will automatically reach wide open so it will not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat. The thermostat is operated by a wax filled container (pellet) which is sealed. When heated coolant 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 powertrain control module’s (PCM) programing 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. For other probable causes, (Refer to 7 COOLING/ENGINE - DIAGNOSIS AND TESTING). Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this (Refer to 7 - COOLING/ENGINE - DIAGNOSIS AND TESTING). ENGINE COOLANT THERMOSTAT - 2.4L REMOVAL (1) Drain cooling system below the thermostat level. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Remove radiator upper hose from the coolant outlet housing (Fig. 7). (3) Remove coolant outlet housing bolts and housing (Fig. 8). (4) Remove thermostat. Discard gasket and clean both gasket sealing surfaces. INSTALLATION (1) Place a new gasket (dipped in clean water) on the coolant outlet connector surface. Position thermostat with air bleed at the 12 o’clock position in thermostat housing (Fig. 8). (2) Position the coolant outlet connector and gasket over the thermostat, making sure thermostat is seated in the thermostat housing. (3) Position outlet connector to thermostat housing and install bolts (Fig. 8). Tighten bolts to 28 N·m (250 in. lbs.). 7 - 24 ENGINE RS ENGINE COOLANT THERMOSTAT - 2.4L (Continued) ENGINE COOLANT THERMOSTAT - 3.3/3.8L REMOVAL (1) Drain cooling system down below the thermostat level. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Remove radiator upper hose from coolant outlet connector (Fig. 9). Fig. 7 RADIATOR HOSES TO ENGINE - 2.4L 1 - UPPER HOSE 2 - LOWER HOSE Fig. 9 RADIATOR HOSES TO ENGINE - 3.3/3.8L 1 - UPPER HOSE 2 - LOWER HOSE Fig. 8 Thermostat and Outlet Connector - 2.4L Engine 1 2 3 4 - THERMOSTAT GASKET COOLANT OUTLET CONNECTOR BOLT (4) Install the radiator upper hose to coolant outlet housing (Fig. 7). (5) Refill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (3) Remove coolant outlet connector bolts and connector (Fig. 10). (4) Remove thermostat from outlet connector. (5) Discard gasket and clean both gasket sealing surfaces. INSTALLATION (1) To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the wall of the outlet connector recess that was created during the staking procedure that held the OEM thermostat in place (Fig. 11). It is not necessary to restake the replacement thermostat into the connector. (2) Position thermostat to coolant outlet connector. Align the two locating notches on thermostat to the connector (Fig. 12). This position will ensure proper location of the thermostat air bleed. ENGINE RS 7 - 25 ENGINE COOLANT THERMOSTAT - 3.3/3.8L (Continued) Fig. 10 THERMOSTAT - 3.3/3.8L ENGINE 1 2 3 4 - COOLANT OUTLET CONNECTOR BOLT THERMOSTAT GASKET Fig. 12 Thermostat Position In Outlet Connector 1 - LOCATING NOTCH 2 - THERMOSTAT 3 - COOLANT OUTLET CONNECTOR RADIATOR DESCRIPTION The radiator is a cross-flow type (horizontal tubes) with design features that provide greater strength along with sufficient heat transfer capabilities to keep the engine satisfactorily cooled. The radiator has plastic side tanks and aluminum cooling tubes. OPERATION The radiator functions as a heat exchanger, using air flow across the exterior of the radiator tubes. This heat is then transferred from the coolant and into the passing air. REMOVAL Fig. 11 Connector Staking Material Removal 1 - STAKE 2 - OUTLET CONNECTOR (3) Position a new gasket over the thermostat and connector making sure thermostat is in proper position and in the recess provided. (4) Install thermostat and connector assembly to the intake manifold (Fig. 10). Tighten bolts to 28 N·m (250 in. lbs.). (5) Install the radiator upper hose to coolant outlet connector (Fig. 9). (6) Refill the cooling system to the proper level. (Refer to 7 - COOLING - STANDARD PROCEDURE) (1) Disconnect negative cable from battery. (2) Remove radiator upper crossmember support. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - REMOVAL) WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. (3) Drain the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (4) Remove the radiator fans. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL) (5) Disconnect coolant reserve/recovery hose. 7 - 26 ENGINE RS RADIATOR (Continued) (6) Remove vapor purge solenoid from mounting bracket. (7) Disconnect upper and lower hoses from the radiator (Fig. 13) or (Fig. 14). Fig. 13 Radiator Hoses to Radiator - 2.4L 1 - UPPER HOSE 2 - LOWER HOSE 3 - HOSE SUPPORT CLIP Fig. 15 Radiator to A/C Condenser Mounting (left mount shown, right similar) 1 - SCREW - A/C CONDENSER SIDE BRACKET TO RADIATOR 2 - LOWER MOUNT 3 - A/C CONDENSER INSTALLATION Fig. 14 Radiator Hoses to Radiator - 3.3/3.8L 1 - UPPER HOSE 2 - LOWER HOSE (8) Remove the A/C condenser side brackets to radiator attaching screws (Fig. 15). Separate the condenser from the radiator by lifting upward to disengage from lower mounts (Fig. 15). Allow the condenser to rest in front of radiator. (9) Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal. (1) Be sure the air seal is in position before radiator is installed. Slide radiator down into position. Seat the radiator with the rubber isolators into the mounting holes provided, with a 10 lbs. force. (2) Position air conditioning condenser onto the radiator lower mounts and install upper screws (Fig. 15). Tighten fasteners to 5 N·m (45 in. lbs.). (3) Install the radiator upper and lower hoses (Fig. 13) or (Fig. 14). (4) Connect the coolant reserve/recovery hose. (5) Connect the vapor purge solenoid to the mounting bracket. (6) Install the radiator fans. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION) (7) Install the radiator upper crossmember support. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - INSTALLATION) (8) Fill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (9) Connect negative cable to battery. ENGINE RS 7 - 27 RADIATOR DRAINCOCK RADIATOR PRESSURE CAP REMOVAL DESCRIPTION CAUTION: Use of pliers on draincock is not recommended. Damage may occur to radiator or draincock. The cooling system pressure cap is located on the radiator. The cap construction includes; stainless steel swivel top, rubber seals, and retainer, main spring, and a spring loaded valve (Fig. 17). NOTE: It is not necessary to remove draincock during a routine coolant drain. (1) Drain the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Open the draincock by turning it counterclockwise until it stops. (3) Turn the draincock back (clockwise) 1/8 turn. (4) Pull the draincock (Fig. 16) from the radiator tank. Fig. 17 Cooling System Pressure Cap Filler Neck 1 2 3 4 5 6 7 8 - OVERFLOW NIPPLE MAIN SPRING GASKET RETAINER STAINLESS-STEEL SWIVEL TOP RUBBER SEALS VENT VALVE RADIATOR FILLER NECK OPERATION Fig. 16 Draincock 1 - RADIATOR TANK 2 - DRAINCOCK INSTALLATION (1) Align draincock stem to radiator tank opening. (2) Push draincock into the radiator tank opening. (3) Tighten the draincock by turning clockwise until it stops. (4) Fill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) The cooling system is equipped with a pressure cap that releases excessive pressure; maintaining a range of 97-124 kPa (14-18 psi). The cooling system will operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased radiator cooling capacity. There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing the coolant to return to cooling system from coolant reserve system tank by vacuum through a connecting hose. If valve is stuck shut, or the coolant recovery hose is pinched, the radiator hoses will be collapsed on cool down. Clean the vent valve (Fig. 17) and inspect coolant recovery hose routing, to ensure proper sealing when boiling point is reached. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve tank. If the gasket is dirty or damaged, a vacuum may not be achieved, resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine. 7 - 28 ENGINE RS RADIATOR PRESSURE CAP (Continued) DIAGNOSIS AND TESTING ket should relieve at 69-124 kPa (10-18 psi) and hold pressure at 55 kPa (8 psi) minimum. DIAGNOSIS AND TESTING - COOLING SYSTEM 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 (Fig. 18). 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 (Fig. 18), 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. Fig. 19 Radiator Pressure Cap Filler Neck 1 2 3 4 5 6 7 8 - OVERFLOW NIPPLE MAIN SPRING GASKET RETAINER STAINLESS-STEEL SWIVEL TOP RUBBER SEALS VENT VALVE RADIATOR FILLER NECK WARNING: THE WARNING WORDS “DO NOT OPEN HOT” ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. There is no need to remove the radiator cap at any time except for the following purposes: (1) Check and adjust coolant freeze point. (2) Refill system with new coolant. (3) Conducting service procedures. (4) Checking for vacuum leaks. Fig. 18 Testing Cooling System Pressure Cap 1 - PRESSURE CAP 2 - PRESSURE TESTER DIAGNOSIS AND TESTING - RADIATOR CAP TO FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple (Fig. 19). Attach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator. Pressure cap upper gas- WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED. ENGINE RS 7 - 29 RADIATOR PRESSURE CAP (Continued) CLEANING Use only a mild soap to clean the pressure cap. INSPECTION Hold the cap in your hand, top side up (Fig. 20). The vent valve at the bottom of the cap should open. If the rubber gasket 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 and the rubber gasket, replace the cap. Do not use a replacement cap that has a spring to hold the vent shut. A replacement cap must be of the type designed for coolant reserve systems. This design ensures coolant return to the radiator. Fig. 20 Cooling System Pressure Cap 1 2 3 4 5 6 7 8 RADIATOR FAN DESCRIPTION - OVERFLOW NIPPLE MAIN SPRING GASKET RETAINER STAINLESS-STEEL SWIVEL TOP RUBBER SEALS VENT VALVE RADIATOR FILLER NECK The dual radiator fans are mounted to the back side of the radiator (Fig. 21). The radiator fan consist of the fan blade, electric motor and a support shroud which are all serviced as an assembly. OPERATION RADIATOR FAN OPERATION CHART COOLANT TEMPERATURE Fan Operation Speeds: Initial A/C PRESSURE Max Initial TRANSAXLE OIL TEMPERATURE Max Initial Max Fan On: 104°C (220°F) 110°C (230°F) Fan Speed Duty-Cycles (Ramps-up) from 30% to 99% 1,724 Kpa (250 psi) 2,068 Kpa (300 psi) Fan Speed Duty-Cycles (Ramps-up) from 30% to 99% 96°C (204°F) 111°C (232°F) Fan Speed Duty Cycles (Ramps-up) from 30% to 99% Fan Off: 101°C (214°F) Fan Speed Duty-Cycles (Rampsdown) from 99% to 30% 1,710 Kpa (248 psi) Fan Speed Duty-Cycles (Rampsdown) from 99% to 30% 89°C (192°F) Fan Speed Duty Cycles (Ramps-down) from 99% to 30% 7 - 30 ENGINE RS RADIATOR FAN (Continued) DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR RADIATOR FAN DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL) 2. Fan blade striking a surrounding object. 2. Locate point of fan blade contact and repair as necessary. 3. Air obstructions at radiator or A/C condenser. 3. Remove obstructions and/or clean debris. 4. Electric fan motor defective. 4. Replace fan assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL) 1. Fan relay, powertrain control module (PCM), coolant temperature sensor, or wiring defective. 1. (Refer to Appropriate Diagnostic Information) Repair as necessary. 2. Defective A/C pressure transducer. 2. (Refer to Appropriate Diagnostic Information) Repair as necessary. 1. Fan relay, powertrain control module (PCM), coolant temperature sensor or wiring defective. 1. (Refer to Appropriate Diagnostic Information) Repair as necessary. 2. Check for low coolant level. 2. Add coolant as necessary. 3. Defective A/C pressure transducer. 3. (Refer to Appropriate Diagnostic Information) Repair as necessary. ELECTRIC FAN MOTOR DOES NOT OPERATE ELECTRIC RADIATOR FAN OPERATES ALL THE TIME REMOVAL There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as an assembly (Fig. 21). (1) Remove the radiator upper crossmember. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - REMOVAL) (2) Disconnect the radiator fan electrical connectors. (3) Remove radiator fan(s) retaining screw (Fig. 21). (4) Remove the radiator fan(s) by lifting upward to release from mounts. INSTALLATION (1) Install the radiator fan(s) into mounts and attaching clips on the radiator. (2) Install radiator fan(s) attaching screws (Fig. 21). Tighten to 5 N·m (45 in. lbs.). (3) Connect the radiator fan(s) electrical connectors. Fig. 21 Radiator Fans 1 2 3 4 5 6 - SCREWS - RADIATOR FAN ATTACHING RADIATOR FAN - RIGHT MOUNT - RIGHT RADIATOR FAN CLIPS - RADIATOR FAN LOWER MOUNT - LEFT RADIATOR FAN RADIATOR FAN - LEFT ENGINE RS 7 - 31 RADIATOR FAN (Continued) (4) Install the radiator upper support crossmember. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - INSTALLATION) (5) Install the upper radiator mounts to the crossmember bolts, if removed. Tighten to 8 N·m (70 in. lbs.). (6) Install the radiator upper hose to the support clip (2.4L engine). (5) Remove the rivet attaching the relay to the front bumper beam (Fig. 22). (6) Remove the relay. RADIATOR FAN RELAY DESCRIPTION The radiator fan relay is a solid state type and is located on the front bumper reinforcment (Fig. 22). Refer to WIRING DIAGRAMS for a circuit schematic. OPERATION The solid state radiator fan relay is controlled by the Powertrain Control Module (PCM) by way of a Pulse Width Modulated (PWM) signal. The relay control circuit supplies a 12 volt signal to the PCM. The PCM then pulses the ground circuit to achieve fan on time. The relay provides a voltage to the fan motors which is proportional to the pulse width it receives from the PCM. The duty cycle ranges from 30% for low speed operation, then ramps-up to 100% for high speed operation. This fan control system provides infinitely variable fan speeds, allowing for improved fan noise, A/C performance, better engine cooling, and additional vehicle power. To control operation of the relay, the PCM looks at inputs from: • Engine coolant temperature • A/C pressure transducer • Ambient temperature from the body controller • Vehicle speed • Transmission oil temperature The PCM uses these inputs to determine when the fan should operate and at what speed. For further information on fan operation, (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - OPERATION). REMOVAL (1) Open hood. (2) Disconnect and isolate the battery negative cable. (3) Remove the radiator crossmember to front fascia closure panel. (4) Disconnect the relay electrical connector (Fig. 22). Fig. 22 Radiator Fan Relay 1 2 3 4 - FRONT FASCIA - FAN RELAY - RIVET - A/C CONDENSER (FRONT SIDE) INSTALLATION CAUTION: The relay mounting location is designed to dissipate heat. Ensure the relay is securely attached to prevent relay “thermal” shutdown and relay damage, resulting in possible engine overheating. (1) (2) (3) (4) Position relay and install a new rivet (Fig. 22). Connect electrical connector to relay. Install closure panel and attaching screws. Connect negative cable to battery. 7 - 32 ENGINE WATER PUMP - 2.4L DESCRIPTION The water pump has a cast aluminum body and housing with a stamped steel impeller. The water pump bolts directly to the block (Fig. 23). The cylinder block to water pump seal is provided by a rubber O-ring. The water pump is driven by the engine timing belt. RS (7) Remove right engine mount bracket (Fig. 24). (8) Remove the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKET(S) - REMOVAL). (9) Remove timing belt idler pulley. (10) Hold camshaft sprocket with Special tool C-4687 and adaptor C-4687-1 while removing bolt. Remove both cam sprockets. (11) Remove the timing belt rear cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL). (12) Remove the generator and bracket (Fig. 24). (13) Remove water pump to engine attaching screws (Fig. 25). CLEANING Clean gasket mating surfaces as necessary. INSPECTION Replace water pump body assembly if it has any of these defects: (1) Cracks or damage on the body. (2) Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body. (3) Loose or rough turning bearing. (4) Impeller rubs either the pump body or the engine block. (5) Impeller loose or damaged. (6) Sprocket or sprocket flange loose or damaged. INSTALLATION (1) Install new O-ring gasket in water pump body O-ring locating groove (Fig. 26). Fig. 23 Water Pump 1 - CYLINDER BLOCK 2 - WATER PUMP OPERATION The water pump is the heart of the cooling system. The coolant is pumped through the engine block, cylinder head, heater core, and radiator. REMOVAL (1) Disconnect negative cable from battery. (2) Raise vehicle on a hoist. (3) Remove the right inner splash shield. (4) Remove the accessory drive belts (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (5) Drain the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). (6) Support engine from the bottom and remove right engine mount. (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may be damaged and cause a coolant leak. (2) Assemble pump body to block and tighten screws to 12 N·m (105 in. lbs.) (Fig. 25). Pressurize cooling system to 103.4 Kpa (15 psi) with pressure tester and check water pump shaft seal and O-ring for leaks. (3) Rotate pump by hand to check for freedom of movement. (4) Install the timing belt rear cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION). (5) Install camshaft sprockets and torque bolts to 101 N·m (75 ft. lbs.) while holding camshaft sprocket with Special tool C-4687 and adaptor C-4687-1. (6) Install timing belt idler pulley and torque mounting bolt to 61 N·m (45 ft. lbs.). ENGINE RS WATER PUMP - 2.4L (Continued) Fig. 24 Generator Bracket 1 2 3 4 - BRACKET - ENGINE MOUNT BOLT GENERATOR BOLT 5 6 7 8 - BOLT TENSIONER - DRIVE BELT BOLT BOLT Fig. 26 Water Pump Body 1 - IMPELLER 2 - WATER PUMP BODY 3 - O-RING LOCATING GROOVE Fig. 25 Water Pump - 2.4L 1 - CYLINDER BLOCK 2 - WATER PUMP 7 - 33 7 - 34 ENGINE RS WATER PUMP - 2.4L (Continued) (7) Install the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKET(S) - INSTALLATION). (8) Install the generator mount bracket. (Fig. 24) (9) Install the generator. (10) Install right engine mount bracket and engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/ RIGHT MOUNT - INSTALLATION). (11) Fill the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). (12) Install the accessory drive belts (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (13) Lower vehicle and connect battery cable. WATER PUMP - 3.3/3.8L DESCRIPTION The water pump has a die-cast aluminum body and a plastic impeller. It bolts directly to the timing chain case cover, using a rubber seal for sealing (Fig. 27). It is driven by the accessory drive belt. OPERATION The water pump is the heart of the cooling system. The coolant is pumped through the engine block, cylinder head, heater core, and radiator. REMOVAL (1) Drain the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Remove the accessory drive belt shield. (3) Remove the accessory drive belt. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL) (4) Remove water pump pulley bolts (Fig. 27). NOTE: To remove the water pump pulley, it MUST first be positioned between water pump housing and drive hub. The pulley can then be removed with the water pump assembly. (5) Rotate pulley until openings in pulley align with water pump drive hub spokes (Fig. 28). Move pulley inward between pump housing and hub (Fig. 28). Fig. 28 Water Pump Pulley Positioning 1 - HUB - WATER PUMP 2 - PULLEY - WATER PUMP Fig. 27 Water Pump - 3.3/3.8L Engine 1 2 3 4 5 - WATER PUMP PULLEY - WATER PUMP BOLT - PULLEY BOLT - WATER PUMP SEAL - WATER PUMP (6) Position pulley to allow access to water pump mounting bolts. Remove water pump mounting bolts (Fig. 29). (7) Remove water pump with the pulley loosely positioned between hub and the pump body. (8) Remove and discard the seal. ENGINE RS 7 - 35 WATER PUMP - 3.3/3.8L (Continued) (9) Clean seal groove and sealing surfaces on pump and timing chain case cover. Take care not to scratch or gouge sealing surfaces. Fig. 29 Water Pump Bolts - 3.3/3.8L Engine (Shown Without Pulley) Fig. 30 Water Pump Inspection - 3.3/3.8L Engine 1 - WATER PUMP 2 - BOLTS CLEANING Clean gasket mating surfaces as necessary. INSPECTION Replace the water pump if it has any of the following defects. (1) Damage or cracks on the pump body. (2) Coolant leaks; this will be evident by a wet stream of coolant running down the pump body and components below. A thin stain below the weep hole reservoir slot (Fig. 30) is considered normal operation. (3) Impeller rubs inside of chain case cover. (4) Excessively loose or rough turning bearing. NOTE: A weepage stain that is black, brown, or grey is considered normal, if it is dry. If the weep appears wet; pressure test the cooling system at 15–18 psi and observe the weep area. If weep area remains unchanged, do not replace the water pump for this condition. Replace the water pump, if a steady flow of engine coolant is evident from the weep hole/reservoir slot (Fig. 30) (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. INSTALLATION (1) Install new seal into water pump housing groove (Fig. 31). Fig. 31 Water Pump Seal 1 - WATER PUMP HOUSING 2 - SEAL 3 - IMPELLER NOTE: The water pump pulley MUST be positioned loosely between the pump housing and drive hub BEFORE water pump installation. (2) Position the water pump pulley loosely between pump housing and drive hub (Fig. 28). (3) Install water pump and pulley to the timing chain case cover (Fig. 27). Tighten water pump bolts to 12 N·m (105 in. lbs.). (4) Position pulley on water pump hub. Install bolts and tighten to 28 N·m (250 in. lbs.) (Fig. 27). 7 - 36 ENGINE RS WATER PUMP - 3.3/3.8L (Continued) (5) Rotate pump by hand to check for freedom of movement. (6) Install the accessory drive belt. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION) (7) Install drive belt shield. (8) Fill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) WATER PUMP INLET TUBE 2.4L DESCRIPTION The 2.4L engine uses a metal tube to connect the engine block to the lower radiator hose and heater return (Fig. 32). The tube has an O-ring for block to tube sealing and bolts attach the tube to the engine block. Fig. 33 Water Pump Inlet Tube Hose Connections 1 - WATER PUMP INLET TUBE 2 - HOSE - HEATER RETURN 3 - COOLANT INLET (2) Lube O-ring with coolant and install inlet tube into the cylinder block opening (Fig. 32). (3) Install the two inlet tube fasteners and tighten to 12 N·m (105 in. lbs.). (4) Connect the radiator lower hose (Fig. 7) and heater hose to inlet tube (Fig. 33). (5) Install the radiator upper hose. (6) Fill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) WATER PUMP INLET TUBE 3.3/3.8L Fig. 32 Water Pump Inlet Tube—2.4L Engine 1 - O-RING 2 - WATER PUMP INLET TUBE REMOVAL (1) Drain the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Remove radiator upper hose to access the hose connections at the inlet tube. (3) Remove radiator lower (Fig. 7) and heater hoses from the inlet tube (Fig. 33). (4) Remove the two fasteners that hold the inlet tube to the block. (5) Rotate tube while removing the tube from the engine block. INSTALLATION (1) Inspect the O-ring for damage before installing the tube into the cylinder block (Fig. 32). REMOVAL (1) Drain the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Raise vehicle on hoist and remove the belt splash shield. (3) Remove the radiator lower hose from inlet tube (Fig. 34). (4) Remove the oil cooler outlet/heater return hose from inlet tube (only if equipped with engine oil cooler) (Fig. 35). (5) Remove the inlet tube bolts (Fig. 36). (6) Remove the inlet tube (Fig. 36). Discard the O-ring seal. INSTALLATION (1) Clean the inlet tube O-ring sealing surfaces on the timing cover housing and tube. (2) Apply Mopart Dielectric Grease or equivalent to the O-ring before installation. (3) Position new O-ring seal on inlet tube (Fig. 36). ENGINE RS 7 - 37 WATER PUMP INLET TUBE - 3.3/3.8L (Continued) Fig. 36 WATER PUMP INLET TUBE Fig. 34 RAD HOSES TO ENGINE - 3.3/3.8L 1 - UPPER HOSE 2 - LOWER HOSE 1 2 3 4 5 - TIMING CHAIN COVER INLET TUBE BOLT BOLT O-RING (4) Install the inlet tube (Fig. 36). Tighten bolts to 28 N·m (250 in. lbs.). (5) Connect radiator lower hose (Fig. 34) and heater return hose (if equipped with engine oil cooler) (Fig. 35) to the inlet tube. (6) Install the drive belt splash shield and lower vehicle. (7) Fill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) Fig. 35 Engine Oil Cooler Hoses (Engine Oil Cooler Equipped) 1 2 3 4 5 - OIL COOLER INLET TUBE INLET HOSE OIL COOLER OUTLET TUBE OUTLET HOSE WATER PUMP INLET TUBE 7 - 38 TRANSMISSION RS TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION STANDARD PROCEDURE - FLUSHING COOLERS AND TUBES . . . . . . . . . . . . . . . . . 38 TRANSMISSION OIL COOLER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 CLEANING . . . . . . . . . . . . . . . . . . INSPECTION ................ INSTALLATION . . . . . . . . . . . . . . . TRANSMISSION OIL COOLER LINES REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . TRANSMISSION (4) Connect the BLUE pressure line to the OUTLET (From) cooler line. (5) Connect the CLEAR return line to the INLET (To) cooler line (6) Turn pump ON for two to three minutes to flush cooler and lines. (7) Turn pump OFF. (8) Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. (9) Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. (10) Place CLEAR suction line into a one quart container of Mopart ATF+4 (Automatic Transmission Fluid—Type 9602). (11) Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. (12) Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. STANDARD PROCEDURE - FLUSHING COOLERS AND TUBES The recommended procedure for cooler flushing is to use Tool 6906 Cooler Flusher. WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87.1–1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIT CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. WARNING: KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. (1) Remove cover plate filler plug on Tool 6906. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Use Mopart Transmission Cooler Flush (MS-552) or equivalent solution conforming to MS-552. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. (2) Reinstall filler plug on Tool 6906. (3) Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. . . . . . . . . . . 39 . . . . . . . . . . 39 . . . . . . . . . . 39 . . . . . . . . . . 39 . . . . . . . . . . 40 TRANSMISSION OIL COOLER DESCRIPTION The transmission oil cooler is an oil-to-air type cooler that is mounted between the front of the radiator and back side of the A/C condenser (Fig. 2). Use only approved transmission oil cooler hoses that are molded to fit the space available. REMOVAL (1) Remove the radiator. (Refer to 7 - COOLING/ ENGINE/RADIATOR - REMOVAL) (2) Disconnect lines from oil cooler (Fig. 1). (3) Remove oil cooler attaching screws (Fig. 2). (4) Remove the oil cooler. TRANSMISSION RS 7 - 39 TRANSMISSION OIL COOLER (Continued) INSTALLATION (1) Install transaxle oil cooler and mounting screws (Fig. 2). NOTE: When replacing the transmission oil cooler, the cooler hoses must be replaced. (2) Connect the new cooler hoses and install clamps (Fig. 1). (3) Install the radiator. (Refer to 7 - COOLING/ ENGINE/RADIATOR - INSTALLATION) (4) Start engine. Check and adjust the fluid level as necessary. Fig. 1 TRANSMISSION COOLER HOSES 1 - TRANSAXLE COOLER HOSES 2 - FITTING - COOLER OUTLET 3 - FITTING - COOLER INLET TRANSMISSION OIL COOLER LINES REMOVAL (1) Using appropriate hose clamp pliers, release tension on clamps and move off fittings. NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the cooler and transaxle, damage to the inner wall of hose will occur. To prevent potential leakage, the cooler hoses must be replaced. (2) Remove the hoses (Fig. 3) or (Fig. 4). Fig. 2 Transmission Oil Cooler 1 - TRANSAXLE OIL COOLER 2 - SCREWS 3 - A/C CONDENSER (REAR SIDE) CLEANING Check the external cooler for debris on the cooling fin surfaces. Clean as necessary. For internal cleaning/flushing procedures, (Refer to 7 - COOLING/ TRANSMISSION - STANDARD PROCEDURE). 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. Fig. 3 TRANS OIL COOLER LINES - 41TE 1 2 3 4 5 - FITTING - COOLER RETURN FITTING - COOLER SUPPLY HOSES - TRANSAXLE COOLER FITTING - COOLER OUTLET FITTING - COOLER INLET 7 - 40 TRANSMISSION RS TRANSMISSION OIL COOLER LINES (Continued) INSTALLATION NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the cooler and transaxle, damage to the inner wall of hose will occur. To prevent potential leakage, the cooler hoses must be replaced. (1) Connect hoses to cooler and transaxle fittings (Fig. 3) or (Fig. 4). (2) Using appropriate pliers, position clamps over fittings and release tension. (3) Start engine and check transaxle fluid level. Adjust fluid level as necessary. Fig. 4 TRANSAXLE OIL COOLER LINES - 31TH 1 2 3 4 5 - FITTING - COOLER RETURN FITTING - COOLER SUPPLY HOSES - TRANSAXLE COOLER FITTING - COOLER OUTLET FITTING - COOLER INLET COOLING 2.5L TURBO DIESEL RG 7a - 1 COOLING 2.5L TURBO DIESEL TABLE OF CONTENTS page COOLING 2.5L TURBO DIESEL DESCRIPTION - COOLING SYSTEM . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST . . . . . . . . . . . . . DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK . . . . . . . . . . DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION . . . . . . . . . . . . . .......1 .......1 .......6 page CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPECIFICATIONS SPECIFICATIONS - TORQUE . . . . . . . . . . . . . 8 SPECIFICATIONS - COOLING SYSTEM CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . . 9 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 .......7 .......7 COOLING 2.5L TURBO DIESEL DIAGNOSIS AND TESTING DESCRIPTION - COOLING SYSTEM DIAGNOSIS AND TESTING - COOLING SYSTEM The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temperature as quickly as possible, maintains normal operating temperature and prevents overheating. The cooling system also provides a means of heating the passenger compartment. The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system. A separate and remotely mounted, pressurized coolant tank using a pressure/vent cap is used. Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following may be the cause: (1) PROLONGED IDLE, VERY HIGH AMBIENT TEMPERATURE, SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED OR STEEP GRADES. Driving techniques that avoid overheating are: • Idle with A/C off when temperature gauge is at end of normal range. • Increasing engine speed for more air flow is recommended. (2) TRAILER TOWING: Consult Trailer Towing section of owners manual. Do not exceed limits. (3) RECENT SERVICE OR ACCIDENT REPAIR: Determine if any recent service has been performed on vehicle that may effect cooling system. This may be: • Engine adjustments (incorrect timing) • Slipping engine accessory drive belt • Brakes (possibly dragging) • Changed parts (incorrect water pump) • Reconditioned radiator or cooling system refilling (possibly under filled or air trapped in system). COOLING SYSTEM COMPONENTS The cooling system consists of: • Charge Air Cooler • Electric Cooling Fans • A aluminum-core radiator with plastic side tanks • A separate pressurized coolant tank • A pressure/vent cap on the coolant tank • Fan shroud • Thermostat • Coolant • Low coolant warning lamp • Coolant temperature gauge • Water pump • Hoses and hose clamps NOTE: If investigation reveals none of the previous items as a cause for an engine overheating complaint, refer to following Cooling System Diagnosis charts. These charts are to be used as a quick-reference only. 7a - 2 COOLING 2.5L TURBO DIESEL RG COOLING 2.5L TURBO DIESEL (Continued) COOLING SYSTEM DIAGNOSIS-DIESEL ENGINE CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS LOW 1. Diesel engines, due to their inherent effiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded. 1. The low gauge reading may be normal. Refer to thermostats in the manual text for information. See Thermostat Diagnosis-Diesel Engine. 2. Is the temperature gauge connected to the temperature gauge coolant sensor on the engine? 2. Check, the engine temperature sensor connector in the engine compartment. 3. Is the temperature gauge operating OK? 3. Check gauge operation. Repair as necessary. 4. Coolant level low in cold ambient temperatures accompanied with poor heater performance. 4. Check coolant level in the coolant tank. Inspect system for leaks. Repair leaks as necessary. Refer to the Coolant section for WARNINGS and precautions before removing the pressure cap. 5. Improper operation of internal heater doors or heater controls. 5. Inspect heater and repair as necessary. Refer to Heating and Air Conditioning for procedures. 1. Trailer is being towed, a steep hill is being climbed, vehicle is operated in slow moving traffic, or engine is being idled with very high ambient (outside) temperature and the air conditioning is on. Higher altitudes could aggravate these conditions. 1. This may be a temporary condition and repair is not necessary. Turn off the air conditioning and attempt to drive the vehicle without any of the previous conditions. Observe the temperature gauge. The gauge should return to the normal range. If the gauge does not return to normal range, determine the cause for the overheating and repair. 2. Temperature gauge reading incorrectly. 2. Check gauge. Refer to I/P group. 3. Coolant low in coolant tank and radiator. 3. Check for coolant leaks and repair as necessary. 4. Pressure cap not installed tightly. If cap is loose, boiling point of coolant will be lowered. 4. Tighten cap. 5. Poor seals at pressure/vent cap. 5. (a) Check condition of cap and cap seals. (b) Check condition of coolant tank filler neck. Make sure it does not leak pressure. TEMPERATURE GAUGE READS HIGH. COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM COOLING SYSTEM COOLING 2.5L TURBO DIESEL RG 7a - 3 COOLING 2.5L TURBO DIESEL (Continued) CONDITION TEMPERATURE GAUGE READING IS INCONSISTENT (FLUCTUATES, CYCLES OR IS ERRATIC) POSSIBLE CAUSES CORRECTION 6. Freeze point of antifreeze not correct. Mixture may be too rich. 6. Check antifreeze. Adjust antifreeze-to-water ratio as required. 7. Coolant not flowing through system. 7. Check for coolant flow in coolant tank with engine warm and thermostat open. Coolant should be observed flowing through the tank. If flow is not observed, determine reason for lack of flow and repair as necessary. 8. Radiator or A/C condensor fins are dirty or clogged. 8. Clean debris from radiator or A/C condensor 9. Radiator core is corroded or plugged. 9. Have radiator re-cored or replaced. 10. Aftermarket A/C installed without proper A/C condensor. 10. Install proper A/C condensor. 11. Dragging Brakes. 11. Check and correct as necessary. 12. Non-factory bug screen is being used reducing airflow. 12. Only a factory screen should be used. 13. Thermostat partially or completely shut. This is more prevalent on high mileage vehicles. 13. Check thermostat and replace if necessary. 14. Cylinder head gasket leaking. 14. Check cylinder head gasket for leaks. 15. Heater core leaking. 15. Check heater cor for leaks. Repair as necessary. 1. During cold weather operation, with the heater blower in the high position, the gauge reading may drop slightly. Fluctuation is also influenced by loads, outside temperature and extended idle time with diesel engines. 1. A normal condition. No correction is necessary. 2. Temperature gauge or engine mounted gauge sensor defective or shorted. Also, corroded or loose wiring in this circuit. 2. Check operation of gauge and repair as necessary. 3. Gauge reading rises when vehicle is brought to a stop after heavy use (engine still running). 3. A normal condition. No correction needed. Gauge should return to normal range after vehicle is driven. 4. Gauge reading high after starting a warm-iup (hot) engine. 4. A normal condition. No correction needed. Gauge should return to normal after a few minutes of engine operation. 7a - 4 COOLING 2.5L TURBO DIESEL RG COOLING 2.5L TURBO DIESEL (Continued) CONDITION PRESSURE CAP IS BLOWING OFF STEAM AND/OR COOLANT. TEMPERATURE GAUGE READING MAY BE ABOVE NORMAL BUT NOT HIGH. COOLANT LEVEL MAY BE HIGH IN COOLANT TANK COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF. GAUGE IS READING HIGH OR HOT HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING NOISY FAN POSSIBLE CAUSES CORRECTION 5. Coolant level low in the coolant tank (air will build up in the cooling system causing the thermostat to open late). 5. Check and correct coolant leaks. 6. Cylinder head gasket leaking allowing exhaust gases to enter the cooling system causing the thermostat to open late. 6. (a) Check for cylinder head gasket leaks with a commercially available leak tester. (b) Check for coolant in engine oil. Inspect for white steam emitting from exhaust system. Repair as necessary. 7. Water pump impeller loose on shaft. 7. Check water pump and replace as necessary. 8. Loose accessory drive belt (water pump slipping). 8. Check and correct as necessary. 9. Air leak on the suction side of the water pump allowing air to build up in the cooling system causing the thermostat to open late. 9. Locate leak and repair as necessary. 1. Pressure relief valve in pressure/ vent cap is defective. 1. Check condition of pressure/vent cap and cap seals. 2. Head gasket leak or cracked cylinder head. 2. Repair as necessary. 1. Coolant leaks in radiator, cooling system hoses, water pump, or engine. 1. Pressure test cooling system and repair as necessary. 1. Vacuum created in cooling system on engine cool-down is not being relieved through pressure/vent cap. 1. Cap relief valve stuck. Replace if necessary. 1. Cooling fan blades loose. 1. Replace cooling fan assembly. 2. Cooling fan blades striking a surrounding object. 2. Locate point of fan blade contact and repair as necessary. 3. Air obstructions at radiator or A/C condensor. 3. Remove obstructions or clean debris from radiator or A/C condensor. COOLING 2.5L TURBO DIESEL RG 7a - 5 COOLING 2.5L TURBO DIESEL (Continued) CONDITION INADEQUATE AIR CONDITIONER PERFORMANCE (COOLING SYSTEM SUSPECTED) INADEQUATE HEATER PERFORMANCE. MAY BE ACCOMPANIED BY LOW GAUGE READING HEAT ODOR POSSIBLE CAUSES CORRECTION 1. Radiator and/or A/C condensor is restricted, obstructed or dirty (insects, leaves, etc.) 1. Remove restriction or clean debris from radiator or A/C condensor. 2. Engine is overheating (heat may be transferred from radiator to A/C condensor. High underhood temperatures due to engine overheating may also transfer heat to A/C condensor). 2. Correct overheating condition. 3. The cooling system is equipped with air seals at the radiator and/or A/C condensor. If these seals are missing or damaged, not enough air flow will be pulled through the radiator and A/C condensor. 3. Check for missing or damaged air seals. Repair as necessary. 1. Diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded. 1. The lower gauge reading may be normal. 2. Coolant level low. 2. Pressure test cooling system. Repair leaks as necessary. 3. Obstruction in heater hose fitting at engine. 3. Remove heater hoses and check for obstructions. Repair as necessary. 4. Heater hose kinked. 4. Locate kinked area. Repair as necessary. 5. Water pump is not pumping water to heater core. When the engine is fully warmed up, both heater hoses should be hot to the touch. If only one of the hoses is hot the water pump may not be operating correctly. The accessory drive belt may also be slipping causing poor water pump operation. 5. Refer to water pumps in this group. Repair as necessary. If a slipping belt is detected, refer to Engine Accessory Drive Belts in this group. Repair as necessary. 1. Various heat shields are used at certain drive line components. One or more of these shields may be missing. 1. Locate missing shields. Repair or replace as necessary. 2. Is temerature gauge reading above the normal range? 2. Refer to the previous Temperature Gauge Reads High in these Diagnostic Charts. Repair as necessary. 3. Is the Cooling fan operating correctly? 3. Refer to Cooling System Fan in this group for diagnosis. Repair as necessary. 7a - 6 COOLING 2.5L TURBO DIESEL RG COOLING 2.5L TURBO DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Has undercoating been applied to any unnecessary components? 4. Clean undercoating as necessary. STEAM IS COMING FROM FRONT OF VEHICLE NEAR GRILL AREA WHEN WEATHER IS WET, ENGINE IS WARMED UP AND RUNNING, AND VEHICLE IS STATIONARY. TEMPERATURE GAUGE IS IN NORMAL RANGE 1. During wet weather, moisture (snow, ice, or rain condensation) on the radiator will evaporate when the thermostat opens. This opening allows heated water into the radiator. When the moisture contacts the hot radiator, steam may be emitted. This usually occurs in cold weather with no fan or airflow to blow it away. 1. Occasional steam emitting from this area is normal. No repair is necessary. COOLANT ODOR 1. Coolant color is not necessarily an indication of adequate corrosion or temperature protection. Do not rely on coolant color for determining condition of coolant. 1. Refer to Coolant in this group for antifreeze tests. Adjust antifreeze-to-water ratio as necessary. COOLANT LEVEL CHANGES IN COOLANT TANK. TEMPERATURE GAUGE IS IN NORMAL RANGE 1. Level changes are to be expected as coolant volume fluctuates with engine temperature. If the level in the tank was between the HOT and COLD marks at normal engine operating temperature, the level should return to within that range after operation at elevated temperatures. 1. This a normal condition. No repair necessary. DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST WARNING: THE WARNING WORDS “DO NOT OPEN HOT” ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. With engine not running, remove pressure/vent cap from the coolant recovery pressure container and wipe the filler neck sealing seat clean. The coolant recovery pressure container should be full. Attach the Cooling System Tester 7700 or equivalent to the radiator, as shown in (Fig. 1) and apply 104 kPa (15 psi) pressure. If the pressure drops more than 13.8 kPa (2 psi) in 2 minutes, inspect all points for external leaks. All radiator and heater hoses should be shaken while at 104 kPa (15 psi), since some leaks occur only while driving due to engine movement. If there are no external leaks, after the gauge dial shows a drop in pressure, detach the tester. Start engine and run until the thermostat opens, allowing the coolant to expand. Reattach the cooling system tester. If the needle on the dial fluctuates it indicates a combustion leak, usually a head gasket leak. WARNING: WITH TOOL IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). If the needle on the dial does not fluctuate, raise the engine rpm a few times. If an abnormal amount of coolant or steam emits from the tailpipe, it may indicate a coolant leak caused by a faulty head gasket, cracked engine block, or cracked cylinder head. There may be internal leaks that can be determined by removing the oil dipstick. If water globules appear intermixed with the oil it will indicate an internal leak in the engine. If there is an internal leak, the engine must be disassembled for repair. RG COOLING 2.5L TURBO DIESEL 7a - 7 COOLING 2.5L TURBO DIESEL (Continued) (2) Remove pressure/vent cap when engine is cold, idle engine until thermostat opens, you should observe coolant flow while looking down in the coolant recovery pressure container. Once flow is detected install the pressure/vent cap. DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION Fig. 1 PRESSURE TESTING COOLING SYSTEM 1 - COOLING SYSTEM PRESSURE TESTER 2 - COOLANT RECOVERY PRESSURE CONTAINER DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK To determine whether coolant is flowing through the cooling system, use the following procedures: (1) If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper radiator hose. If it is hot, coolant is circulating. WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Low coolant level in a cross flow radiator will equalize in both tanks with engine off. With engine at running and at operating temperature, the high pressure inlet tank runs full and the low pressure outlet tank drops, resulting in cooling system aeration. Aeration will draw air into the water pump resulting in the following: • High reading shown on the temperature gauge. • Loss of coolant flow through the heater core. • Corrosion in the cooling system. • Water pump seal may run dry, increasing the risk of premature seal failure. • Combustion gas leaks into the coolant can also cause the above problems. CLEANING Drain cooling system and refill with clean water. Refer to procedures in this section. Run engine with pressure/vent cap installed until upper radiator hose is hot. Stop engine and drain water from system. If water is dirty; fill, run, and drain system again, until water runs clear. INSPECTION After performing a cleaning/flush procedure, inspect all hoses, clamps and connections for deterioration and leaks. Inspect radiator and heater core for leaks. 7a - 8 COOLING 2.5L TURBO DIESEL RG COOLING 2.5L TURBO DIESEL (Continued) SPECIFICATIONS SPECIFICATIONS - TORQUE 2.5L DIESEL - TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Water Pump Housing Nuts 24.4 18 215 Thermostat Housing Bolts 27.5 21 — Accessory Drive Belt Tensioner Bolt 47.1 35 — Accessory Drive Belt Idler Bolt 53 39 — SPECIFICATIONS - COOLING SYSTEM CAPACITY SPECIFICATIONS DESCRIPTION SPECIFICATION Cooling System With Auxiliary Heater 16.6 Liters (17.5 qts.) Cooling System With Out Auxiliary Heater 13.8 Liters (14.6 qts.) ACCESSORY DRIVE RG 7a - 9 ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE SPECIFICATIONS - ACCESSORY BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 BELT TENSIONER REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 IDLER PULLEY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 DRIVE BELTS DESCRIPTION DESCRIPTION - ACCESSORY DRIVE BELT . 10 DESCRIPTION - POWER STEERING BELT . . 10 OPERATION OPERATION-ACCESSORY DRIVE BELT . . . . 10 OPERATION-POWER STEERING BELT . . . . . 10 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL REMOVAL-ACCESSORY DRIVE BELT . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION INSTALLATION-ACCESSORY DRIVE BELT . . 13 INSTALLATION-POWER STEERING BELT . . . 13 ACCESSORY DRIVE SPECIFICATIONS - ACCESSORY BELT TENSION ACCESSORY DRIVE BELT GAUGE 2.5L DIESEL ENGINE A/C Compressor/ Generator Power Steering Belt Dynamic Tensioner 300 N (67 lbs.) BELT TENSIONER REMOVAL WARNING:: BECAUSE OF HIGH SPRING TENSION, DO NOT ATTEMPT TO DISASSEMBLE THE AUTOMATIC BELT TENSIONER. THE TENSIONER IS SERVICED AS AN ASSEMBLY. (1) Remove the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (2) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (3) Remove the belt tensioner retaining bolt and remove tensioner (Fig. 1). INSTALLATION (1) Install belt tensioner and retaining bolt (Fig. 1). Torque bolt to 47 N·m (35ft. lbs.). Fig. 1 BELT TENSIONER AND IDLER PULLEY 1 - BELT TENSIONER RETAINING BOLT 2 - BELT TENSIONER 3 - IDLER PULLEY 4 - VIBRATION DAMPER/CRANKSHAFT PULLEY 5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING BOLTS (2) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (3) Install the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). - 7a - 10 ACCESSORY DRIVE IDLER PULLEY REMOVAL (1) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). CAUTION: IDLER PULLEY RETAINING BOLT HAS LEFT HAND THREAD RG DRIVE BELTS DESCRIPTION DESCRIPTION - ACCESSORY DRIVE BELT The accessory drive belt is a serpentine type belt (Fig. 3). Satisfactory performance of these belts depends on belt condition and proper belt tension. (2) Remove the idler pulley (Fig. 2). Fig. 3 ACCESSORY DRIVE BELT ROUTING Fig. 2 BELT TENSIONER AND IDLER PULLEY 1 - BELT TENSIONER RETAINING BOLT 2 - BELT TENSIONER 3 - IDLER PULLEY 4 - VIBRATION DAMPER/CRANKSHAFT PULLEY 5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING BOLTS INSTALLATION (1) Install the idler pulley (Fig. 2). Torque retaining bolt to 22 N·m (16 ft. lbs.). (2) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (3) Install the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). 1 2 3 4 5 6 7 8 - GENERATOR - IDLER PULLEY - A/C COMPRESSOR CLUTCH - POWER STEERING PUMP PULLEY - POWER STEERING BELT - CRANKSHAFT DAMPER/PULLEY - BELT TENSIONER - ACCESSORY DRIVE BELT DESCRIPTION - POWER STEERING BELT The power steering belt is a serpentine type belt (Fig. 3). Satisfactory performance of this belt depends on condition of the belt. OPERATION OPERATION-ACCESSORY DRIVE BELT The accessory drive belts form the link between the engine crankshaft and the engine driven accessories. OPERATION-POWER STEERING BELT The power steering belt forms a link between the engine crankshaft and the power steering pump. ACCESSORY DRIVE RG 7a - 11 DRIVE BELTS (Continued) DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT CONDITION INSUFFICIENT ACCESSORY OUTPUT DUE TO BELT SLIPPAGE BELT SQUEAL WHEN ACCELERATING ENGINE BELT SQUEAK AT IDLE BELT ROLLED OVER IN GROOVE OR BELT JUMPS OFF POSSIBLE CAUSES CORRECTIONS 1. Belt too loose 1. (a) Replace belt (auto-tensioned belts) 2. Faulty belt tensioner 2. Replace tensioner as necessary 3. Belt excessively glazed or worn 3. Replace belt 1. Belts too loose 1. Check and replace belt tensioner if necessary 2. Belt glazed 2. Replace belt 1. Belts too loose 1. (a) Replace belt 2. Dirt or paint imbedded in belt 2. Replace belt 3. Non-uniform belt 3. Replace belt 4. Misaligned pulleys 4. Align accessories 5. Non-uniform groove or eccentric pulley 5. Replace pulley 1. Broken cord in belt 1. Replace belt 2. Belt too loose, or too tight 2. Replace belt 3. Misaligned pulleys 3. Align accessories 4. Non-uniform groove or eccentric pulley 4. Replace pulley REMOVAL REMOVAL-ACCESSORY DRIVE BELT (1) Remove the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (2) Relieve tension on belt tensioner using a suitable wrench (Fig. 4) and lock tensioner with a drift punch (Fig. 5). (3) Remove the accessory drive belt. REMOVAL (1) Raise vehicle on hoist. (2) Remove right front fender inner splash shield. (3) Install power steering belt remover tool on crankshaft damper (Fig. 6). (4) Rotate engine clockwise to remove belt (Fig. 7). 7a - 12 ACCESSORY DRIVE RG DRIVE BELTS (Continued) Fig. 4 ACCESSORY DRIVE BELT REMOVAL 1 2 3 4 5 6 - BELT TENSIONER - ACCESSORY DRIVE BELT - IDLER PULLEY - A/C COMPRESSOR CLUTCH - CRANKSHAFT DAMPER/PULLEY - WRENCH Fig. 6 POWER STEERING BELT REMOVAL TOOL 1 2 3 4 - VIBRATION DAMPER POWER STEERING PULLEY POWER STEERING BELT POWER STEERING BELT REMOVER Fig. 7 POWER STEERING BELT REMOVAL Fig. 5 LOCKING/LOCKING BELT TENSIONER 1 - VIBRATION DAMPER 2 - POWER STEERING BELT 3 - POPWER STEERING BELT REMOVER ACCESSORY DRIVE RG 7a - 13 DRIVE BELTS (Continued) INSTALLATION INSTALLATION-ACCESSORY DRIVE BELT (1) Install the accessory drive belt in proper popsition (Fig. 8). Fig. 9 LOCKING/UNLOCKING BELT TENSIONER Fig. 8 ACCESSORY DRIVE BELT ROUTING 1 2 3 4 5 6 7 8 - GENERATOR - IDLER PULLEY - A/C COMPRESSOR CLUTCH - POWER STEERING PUMP PULLEY - POWER STEERING BELT - CRANKSHAFT DAMPER/PULLEY - BELT TENSIONER - ACCESSORY DRIVE BELT (2) Unlock belt tensioner by removing punch and apply tension to accessory drive belt (Fig. 9). (3) Install the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). INSTALLATION-POWER STEERING BELT (1) Install power steering belt installation tool (Fig. 10). (2) Install power steering belt on crankshaft and rotate crankshaft clockwise until belt is fully installed on crankshaft (Fig. 10). (3) Remove installation tool from crankshaft. (4) Install right front fender inner splash shield. (5) Lower vehicle from hoist. Fig. 10 POWER STEERING BELT INSTALLATION 1 2 3 4 5 - POWER STEERING BELT HOLDING HOOK POWER STEERING PUMP PULLEY VIBRATION DAMPER POWER STEERING BELT INSTALLATION TOOL 7a - 14 ENGINE RG ENGINE TABLE OF CONTENTS page COOLANT DESCRIPTION . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE - COOLANT SERVICE . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT . . . . . . . . . . . . STANDARD PROCEDURE - COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - COOLING SYSTEM FILLING . . . . . . . . . . . . . . . . STANDARD PROCEDURE - COOLING SYSTEM DRAINING. . . . . . . . . . . . . . . COOLANT RECOVERY PRESS CONTAINER DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT TEMP SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT THERMOSTAT DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . RADIATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . RADIATOR DRAINCOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . WATER PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . 15 . . . . . 16 . . . . . 16 . . . . . 16 . . . . . 16 . . . . . 17 . . . . . . . . . . . . . . . . . 17 . 17 . 18 . 18 . . . . . . . . . . . . . . . . . 19 . 19 . 19 . 19 . . . . . . . . . . . . . . . . . 20 . 20 . 20 . 20 . . . . . . . . . . . . . . . . . 21 . 21 . 21 . 22 . . . . . 22 . . . . . 22 . . . . . 23 page OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - WATER PUMP . . . . . . . . . . . . REMOVAL - WATER PUMP HOUSING . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION - WATER PUMP ........ INSTALLATION - WATER PUMP HOUSING RADIATOR PRESSURE CAP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP. . . . . . . . . . . . . DIAGNOSIS AND TESTING - PRESSURE RELIEF TEST . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ........................ RADIATOR FAN DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . HOSE CLAMPS DESCRIPTION - HOSE CLAMPS ......... OPERATION - HOSE CLAMPS . . . . . . . . . . . RADIATOR FAN RELAY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT SYSTEM HOSES REMOVAL REMOVAL - UPPER RADIATOR HOSE . . . REMOVAL - LOWER RADIATOR HOSE . . . REMOVAL - COOLANT BYPASS HOSE . . . INSTALLATION INSTALLATION - UPPER RADIATOR HOSE INSTALLATION - LOWER RADIATOR HOSE INSTALLATION - COOLANT BYPASS HOSE . . 23 . . 23 . . 23 . . 23 . . 23 . . 24 . . 25 . . 25 . . 25 . . 26 . . 26 . . 26 . . 26 . . 27 . . 27 . . 28 . . 28 . . 28 . . 28 . . 29 . . 29 . . 29 . . 29 . . 30 . . 30 . 30 . 30 RG COOLANT DESCRIPTION Coolant flows through the engine water jackets and cylinder heads absorbing heat produced by the engine during operation. The coolant carries heat to the radiator and heater core. Here it is transferred to ambient air passing through the radiator and heater core fins. The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37 deg. C (-35 deg. F). 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 percent antifreeze concentration, which prevents freezing down to -67.7 deg. C (-90 deg. 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. 100 Percent Ethylene-Glycol—Should Not Be Used in Chrysler Vehicles 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 deg. C (300 deg. 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 deg. C (-8 deg. F ). Propylene-glycol Formulations—Should Not Be Used in Chrysler Vehicles Propylene-glycol formulations do not meet Chrysler coolant specifications. 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 deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol’s freeze point. The boiling point (protection against summer boil-over) of propyleneglycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This ENGINE 7a - 15 can increase cylinder head temperatures under certain conditions. Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be Used in Chrysler Vehicles 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. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. DIAGNOSIS AND 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 -59°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 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. 7a - 16 ENGINE RG STANDARD PROCEDURE STANDARD PROCEDURE - COOLANT SERVICE For engine coolant recommended service schedule, (Refer to LUBRICATION & MAINTENANCE/MAINTENANCE SCHEDULES - DESCRIPTION). STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT The pressure/vent cap should not be removed from the coolant recovery pressure container when the engine is hot. When additional coolant is needed to maintain this level, it should be added to the coolant recovery pressure container (Fig. 1). Use only 50/50 mix of ethylene glycol type antifreeze and distilled water. For the recommeded antifreeze/coolant type (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. For the recommeded antifreeze/coolant type (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES DESCRIPTION). STANDARD PROCEDURE - COOLANT LEVEL CHECK NOTE: Do not remove pressure/vent cap for routine coolant level inspections. The coolant reserve system provides a quick visual method for determining the coolant level without removing the pressure/vent cap. With the engine cold and not running, simply observe the level of the coolant in the coolant recovery pressure container (Fig. 2). The coolant level should be between the MIN and MAX marks. STANDARD PROCEDURE - COOLING SYSTEM FILLING (1) Remove pressure vent cap from coolant recovery pressure container. (2) Loosen air bleed screw on the thermostat housing (Fig. 9). (3) Slowly fill the cooling through the coolant recovery pressure container until a steady stream of coolant comes out of the air bleed. (4) Tighten the air bleed screw. Fig. 1 UNDERHOOD FLUID FILL LOCATIONS 1 2 3 4 5 - COOLANT PRESSURE/VENT CAP BRAKE MASTER CYLINDER INTELLIGENT POWER MODULE BATTERY COOLANT RECOVERY PRESSURE CONTAINER 6 7 8 9 - OIL DIPSTICK - WINDSHIELD SOLVENT RESEVOIR - AIR FILTER HOUSING - ENGINE OIL FILL CAP ENGINE RG 7a - 17 COOLANT (Continued) (1) Without removing pressure/vent cap and with system not under pressure, open the draincock. The draincock is located on the lower right side of radiator (Fig. 3). (2) After the coolant recovery pressure container is empty, then remove coolant pressure/vent cap. Fig. 2 COOLANT RECOVERY PRESSURE CONTAINER LOCATION 1 - PRESSURE/VENT CAP 2 - BRAKE MASTER CYLINDER 3 - BATTERY 4 - BATTERY SHIELD 5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING CLIP 6 - ENGINE COVER 7 - COOLANT RECOVERY PRESSURE CONTAINER (5) Continue filling coolant recovery pressure container until level reaches the full line. (6) Without installing the pressure/vent cap, start and run engine at idle for a couple minutes. (7) Recheck coolant level and fill as necessary. (8) Install pressure/vent cap and drive vehicle for approx. 10 km to reach normal operating temperatures. (9) Allow vehicle to cool. Check and fill coolant as needed. STANDARD PROCEDURE - COOLING SYSTEM DRAINING WARNING: DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE/VENT CAP, CYLINDER BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN THE SYSTEM IS HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR. Fig. 3 DRAINCOCK LOCATION 1 2 3 4 - RADIATOR DRAINCOCK LOWER RADIATOR SUPPORT ELECTRIC COOLING FAN COOLANT RECOVERY PRESS CONTAINER DESCRIPTION The coolant recovery pressure container is mounted in the engine compartment next to the battery. The coolant recovery pressure container is made of plastic (Fig. 4). OPERATION The coolant recovery pressure container works with the pressure/vent cap to use thermal expansion and contraction of the coolant to keep the coolant free of trapped air. Provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure without removing the pressure/vent cap. It also provides some reserve coolant to cover deaeration, evaporation, or boiling losses. 7a - 18 ENGINE RG COOLANT RECOVERY PRESS CONTAINER (Continued) Fig. 4 COOLANT RECOVERY PRESSURE CONTAINER LOCATION 1 - PRESSURE/VENT CAP 2 - BRAKE MASTER CYLINDER 3 - BATTERY 4 - BATTERY SHIELD 5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING CLIP 6 - ENGINE COVER 7 - COOLANT RECOVERY PRESSURE CONTAINER Fig. 5 COOLANT RECOVERY PRESSURE CONTAINER LOCATION 1 - PRESSURE/VENT CAP 2 - BRAKE MASTER CYLINDER 3 - BATTERY 4 - BATTERY SHIELD 5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING CLIP 6 - ENGINE COVER 7 - COOLANT RECOVERY PRESSURE CONTAINER REMOVAL INSTALLATION (1) Drain cooling system below level of coolant recovery pressure bottle. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) (2) Disconnect coolant bypass and overflow hoses from coolant recovery pressure container (Fig. 6). (3) Unclip the coolant recovery pressure container retaining clip (Fig. 5). (4) Raise coolant recovery pressure container from mounting bracket and disconnect coolant hose from bottom of container (Fig. 6). (5) Remove coolant recovery pressure bottle. (1) Connect coolant hose at bottom of coolant recovery pressure container (Fig. 6) and install in mounting bracket. (2) Connect coolant recovery pressure container retaining clip (Fig. 5). (3) Connect coolant bypass and overflow hoses to coolant recovery pressure container. (4) Refill cooling system. (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE) ENGINE RG 7a - 19 COOLANT RECOVERY PRESS CONTAINER (Continued) Fig. 6 COOLANT RECOVERY PRESSURE CONTAINER 1 2 3 4 - COOLANT RECOVERY PRESSURE CONTAINER COOLANT BYPASS HOSE OUTLET HOSE PRESSURE/VENT CAP ENGINE COOLANT TEMP SENSOR Fig. 7 COOLANT TEMPERATURE SENSOR LOCATION 1 2 3 4 5 - EGR SOLENOID UPPER RADIATOR HOSE COOLANT TEMPERATURE SENSOR INTAKE MANIFOLD INLET INTAKE MANIFOLD/CYLINDER HEAD COVER The engine coolant temperature sensor threads into a coolant passage in the cylinder head (Fig. 7). New sensors have sealant applied to the threads. (1) Drain the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) (2) Disconnect coolant temperature sensor electrical connector (Fig. 8). (3) Remove coolant temperature sensor from cylinder head (Fig. 8). OPERATION INSTALLATION The coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor (resistance varies inversley with temperature). This means at cold tempertures its resistance is high so the voltage signal will be high. As coolant temperture increases, resistance decreases and the signal voltage will be low. This allows the sensor to provide an analog voltage signal to the ECM. (1) Install coolant temperature sensor in cylinder head (Fig. 8). (2) Connect coolant temperature sensor electrical connector (Fig. 8). (3) Refill the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) (4) Connect the negative battery cable. DESCRIPTION REMOVAL WARNING: DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE/VENT CAP, CYLINDER BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN THE SYSTEM IS HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR. 7a - 20 ENGINE RG ENGINE COOLANT THERMOSTAT (Continued) Fig. 8 COOLANT TEMPERATURE SENSOR LOCATION 1 2 3 4 5 - EGR SOLENOID UPPER RADIATOR HOSE COOLANT TEMPERATURE SENSOR INTAKE MANIFOLD INLET INTAKE MANIFOLD/CYLINDER HEAD COVER Fig. 9 THERMOSTAT HOUSING LOCATION 1 - CYLINDER HEAD COVER 2 - THERMOSTAT HOUSING 3 - AIR BLEED 4 - WATER PUMP 5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING BYPASS HOSE 6 - EGR VALVE ENGINE COOLANT THERMOSTAT REMOVAL DESCRIPTION NOTE: The thermostat is not serviced separately. The thermostat and housing must be replaced as an assembly. A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator (Fig. 9). OPERATION The thermostat starts to open at 80°C (176°F). Above this temperature, coolant is allowed to flow to the radiator. This provides quicker engine warmup and overall temperature control. The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes other problems. These are: longer engine warmup time, unreliable warmup performance, increased exhaust emissions and crankcase condensation. This condensation can result in sludge formation. (1) Disconnect negative battery cable. (2) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (3) Remove front wiper unit to gain access to thermostat housing(Refer to 8 - ELECTRICAL/WIPERS/ WASHERS/WIPER MODULE - REMOVAL). (4) Disconnect upper radiator hose adapter tube, water pump hose, and EGR hose at thermostat housing. (5) Remove both thermostat housing attaching bolts and housing (Fig. 10). INSTALLATION (1) Install thermostat housing, gasket, and retaining bolts (Fig. 10). Torque bolts to 27.5N·m. (2) Connect upper radiator hose adapter tube, water pump hose, and EGR cooler hose to thermostat housing. ENGINE RG 7a - 21 ENGINE COOLANT THERMOSTAT (Continued) REMOVAL (1) Disconnect negative cable from battery. (2) Remove radiator upper crossmember support. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - REMOVAL) WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. (3) Drain the cooling system (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE). (4) Remove the radiator fans. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL) (5) Disconnect coolant bypass hose (Fig. 11). (6) Disconnect upper and lower hoses from the radiator (Fig. 11). Fig. 10 THERMOSTAT HOUSING ASSEMBLY 1 2 3 4 5 - THERMOSTAT HOUSING GASKET THERMOSTAT HOUSING RETAINING BOLTS CYLINDER HEAD CYLINDER HEAD COVER/INTAKE MANIFOLD (3) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (4) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (5) Connect negative battery cable. RADIATOR DESCRIPTION The radiator is a cross-flow type (horizontal tubes) with design features that provide greater strength along with sufficient heat transfer capabilities to keep the engine satisfactorily cooled. The radiator has plastic side tanks and aluminum cooling tubes. OPERATION The radiator functions as a heat exchanger, using air flow across the exterior of the radiator tubes. This heat is then transferred from the coolant and into the passing air. Fig. 11 UPPER AND LOWER RADIATOR HOSES 1 2 3 4 5 6 7 - COOLANT BYPASS HOSE RADIATOR ASSEMBLY UPPER RADIATOR HOSE COOLING FAN LOWER RADIATOR HOSE CHARGE AIR COOLER RADIATOR BRACKET (7) Remove the A/C condenser side brackets to radiator attaching screws (Fig. 12). Separate the condenser from the radiator by lifting upward to disengage from lower mounts (Fig. 12). Allow the condenser to rest in front of radiator. 7a - 22 ENGINE RG RADIATOR (Continued) (8) Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal. RADIATOR DRAINCOCK 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 (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE). (2) Open the draincock by turning it counterclockwise until it stops. (3) Turn the draincock back (clockwise) 1/8 turn. (4) Pull the draincock (Fig. 13) from the radiator tank. Fig. 12 Radiator to A/C Condenser Mounting (left mount shown, right similar) 1 - SCREW - A/C CONDENSER SIDE BRACKET TO RADIATOR 2 - LOWER MOUNT 3 - A/C CONDENSER INSTALLATION (1) Be sure the air seal is in position before radiator is installed. Slide radiator down into position. Seat the radiator with the rubber isolators into the mounting holes provided, with a 10 lbs. force. (2) Position air conditioning condenser onto the radiator lower mounts and install upper screws (Fig. 12). Tighten fasteners to 5 N·m (45 in. lbs.). (3) Install the radiator upper and lower hoses (Fig. 11). (4) Connect the coolant bypass hose. (5) Install the radiator fans. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION) (6) Install the radiator upper crossmember support. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - INSTALLATION) (7) Fill the cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (8) Connect negative cable to battery. Fig. 13 Draincock 1 - RADIATOR TANK 2 - DRAINCOCK INSTALLATION (1) Align draincock stem to radiator tank opening. (2) Push draincock into the radiator tank opening. (3) Tighten the draincock by turning clockwise until it stops. (4) Fill the cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). ENGINE RG 7a - 23 WATER PUMP DESCRIPTION The water pump on the 2.5L CRD diesel has a die cast aluminum housing. It bolts to a aluminum housing which attaches to the engine block (Fig. 14). Fig. 15 WATER PUMP LOCATION 1 2 3 4 5 Fig. 14 WATER PUMP 1 2 3 4 5 6 7 - WATER PUMP HOUSING STUDS WATER PUMP RETAINING NUTS OIL COOLER RETAINING STUD OIL COOLER TO ENGINE BLOCK RETAINING BOLT OIL COOLER COOLANT HOSE ENGINE BLOCK OPERATION The water pump is used to circulate coolant through the cooling system. The coolant is pumped through the engine block, cylinder head, heater core, EGR cooler, cabin heater, and radiator. - CYLINDER HEAD ENGINE BLOCK OIL COOLER OIL FILTER HOUSING WATER PUMP REMOVAL - WATER PUMP HOUSING (1) Disconnect negative battery cable. (2) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (3) Remove both outer and inner timing belt covers (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (4) Disconnect water pump housing to thermostat housing bypass hose (Fig. 16). (5) Remove the water pump housing retaining nuts (Fig. 17). (6) Remove water pump housing from engine block (Fig. 17). CLEANING REMOVAL REMOVAL - WATER PUMP (1) Disconnect negative battery cable. (2) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (3) Remove timing belt inner and outer covers (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (4) Remove water pump retaining bolts and pump (Fig. 15). Clean gasket mating surfaces as necessary. INSTALLATION INSTALLATION - WATER PUMP (1) Clean gasket mating surfaces as necessary. (2) Place water pump and gasket in place. Install water pump retaining bolts (Fig. 15). Torque bolts to 24.4N·m. 7a - 24 ENGINE RG WATER PUMP (Continued) Fig. 16 THERMOSTAT HOUSING LOCATION 1 - CYLINDER HEAD COVER 2 - THERMOSTAT HOUSING 3 - AIR BLEED 4 - WATER PUMP 5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING BYPASS HOSE 6 - EGR VALVE Fig. 17 WATER PUMP ASSEMBLY 1 2 3 4 5 6 7 - WATER PUMP HOUSING STUDS WATER PUMP RETAINING NUTS OIL COOLER RETAINING STUD OIL COOLER TO ENGINE BLOCK RETAINING BOLT OIL COOLER COOLANT HOSE ENGINE BLOCK (3) Install both inner and outer timing belt covers (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (4) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (5) Connect negative battery cable. INSTALLATION - WATER PUMP HOUSING (1) Clean mating serfaces of water pump housing and engine block as necessary. (2) Place new o-ring in groove in water pump housing (Fig. 18). (3) Be sure lower radiator hose tube o-ring is in place. (4) Install water pump housing on lower radiator hose tube and push on mounting studs (Fig. 17). Torque retaining nuts to 24.4N·m. (5) Connect water pump housing to thermostat housing bypass hose (Fig. 16). (6) Install both inner and outer timing belt covers (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (7) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (8) Connect negative battery cable. Fig. 18 WATER PUMP HOUSING O-RING 1 - WATER PUMP 2 - WATER PUMP HOUSING O-RING 3 - WATER PUMP HOUSING ENGINE RG 7a - 25 RADIATOR PRESSURE CAP DIAGNOSIS AND TESTING DESCRIPTION DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP The cooling system pressure cap is located on the radiator. The cap construction includes; stainless steel swivel top, rubber seals, and retainer, main spring, and a spring loaded valve (Fig. 19). 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. Fig. 19 Cooling System Pressure Cap Filler Neck 1 2 3 4 5 6 7 8 - OVERFLOW NIPPLE MAIN SPRING GASKET RETAINER STAINLESS-STEEL SWIVEL TOP RUBBER SEALS VENT VALVE PRESSURE BOTTLE FILLER NECK If the pressure cap tests properly while positioned on Cooling System Tester (Fig. 20), 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. OPERATION The cooling system is equipped with a pressure cap that releases excessive pressure; maintaining a range of 97-124 kPa (14-18 psi). The cooling system will operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased radiator cooling capacity. There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing the coolant to return to cooling system from coolant reserve system tank by vacuum through a connecting hose. If valve is stuck shut, or the coolant recovery hose is pinched, the radiator hoses will be collapsed on cool down. Clean the vent valve (Fig. 19) and inspect coolant recovery hose routing, to ensure proper sealing when boiling point is reached. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve tank. If the gasket is dirty or damaged, a vacuum may not be achieved, resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine. Fig. 20 Testing Cooling System Pressure Cap 1 - PRESSURE CAP 2 - PRESSURE TESTER 7a - 26 ENGINE RG RADIATOR PRESSURE CAP (Continued) DIAGNOSIS AND TESTING - PRESSURE RELIEF TEST The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple (Fig. 21). Attach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold pressure at 55 kPa (8 psi) minimum. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED. CLEANING Use only a mild soap to clean the pressure cap. INSPECTION Fig. 21 Radiator Pressure Cap Filler Neck 1 2 3 4 5 6 7 8 - OVERFLOW NIPPLE MAIN SPRING GASKET RETAINER STAINLESS-STEEL SWIVEL TOP RUBBER SEALS VENT VALVE PRESSURE BOTTLE FILLER NECK WARNING: THE WARNING WORDS “DO NOT OPEN HOT” ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. There is no need to remove the radiator cap at any time except for the following purposes: (1) Check and adjust coolant freeze point. (2) Refill system with new coolant. (3) Conducting service procedures. (4) Checking for vacuum leaks. Hold the cap in your hand, top side up (Fig. 21). The vent valve at the bottom of the cap should open. If the rubber gasket 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 and the rubber gasket, replace the cap. Do not use a replacement cap that has a spring to hold the vent shut. A replacement cap must be of the type designed for coolant reserve systems. This design ensures coolant return to the radiator. RADIATOR FAN DESCRIPTION The dual radiator fans are mounted to the back side of the radiator (Fig. 22). The radiator fan consist of the fan blade, electric motor and a support shroud which are all serviced as an assembly. ENGINE RG 7a - 27 RADIATOR FAN (Continued) OPERATION RADIATOR FAN OPERATION CHART COOLANT TEMPERATURE Fan Operation Speeds: Initial A/C PRESSURE Max Initial Max Fan On: 104°C (220°F) 110°C (230°F) Fan Speed Duty-Cycles (Ramps-up) from 30% to 99% 1,724 Kpa (250 psi) 2,068 Kpa (300 psi) Fan Speed Duty-Cycles (Ramps-up) from 30% to 99% Fan Off: 101°C (214°F) Fan Speed Duty-Cycles (Ramps-down) from 99% to 30% 1,710 Kpa (248 psi) Fan Speed Duty-Cycles (Ramps-down) from 99% to 30% DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR RADIATOR FAN DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL) 2. Fan blade striking a surrounding object. 2. Locate point of fan blade contact and repair as necessary. 3. Air obstructions at radiator or A/C condenser. 3. Remove obstructions and/or clean debris. 4. Electric fan motor defective. 4. Replace fan assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL) 1. Fan relay, powertrain control module (PCM), coolant temperature sensor, or wiring defective. 1. (Refer to Appropriate Diagnostic Information) Repair as necessary. 2. Defective A/C pressure transducer. 2. (Refer to Appropriate Diagnostic Information) Repair as necessary. 1. Fan relay, powertrain control module (PCM), coolant temperature sensor or wiring defective. 1. (Refer to Appropriate Diagnostic Information) Repair as necessary. 2. Check for low coolant level. 2. Add coolant as necessary. 3. Defective A/C pressure transducer. 3. (Refer to Appropriate Diagnostic Information) Repair as necessary. ELECTRIC FAN MOTOR DOES NOT OPERATE ELECTRIC RADIATOR FAN OPERATES ALL THE TIME 7a - 28 ENGINE RG RADIATOR FAN (Continued) REMOVAL There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as an assembly (Fig. 22). (1) Remove the radiator upper crossmember. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - REMOVAL) (2) Disconnect the radiator fan electrical connectors. (3) Remove radiator fan(s) retaining screw (Fig. 22). (4) Remove the radiator fan(s) by lifting upward to release from mounts. replace with the original Mopart equipment spring type clamp. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter (Fig. 23). Fig. 23 Spring Clamp Size Location Fig. 22 Radiator Fans 1 2 3 4 5 6 - SCREWS - RADIATOR FAN ATTACHING RADIATOR FAN - RIGHT MOUNT - RIGHT RADIATOR FAN CLIPS - RADIATOR FAN LOWER MOUNT - LEFT RADIATOR FAN RADIATOR FAN - LEFT INSTALLATION 1 - SPRING CLAMP SIZE LOCATION OPERATION - HOSE CLAMPS The spring type hose clamp applies constant tension on a hose connection. To remove a spring type hose clamp, use Special Tool 6094 or equivalent, constant tension clamp pliers (Fig. 24) to compress the hose clamp. (1) Install the radiator fan(s) into mounts and attaching clips on the radiator. (2) Install radiator fan(s) attaching screws (Fig. 22). Tighten to 5 N·m (45 in. lbs.). (3) Connect the radiator fan(s) electrical connectors. (4) Install the radiator upper support crossmember. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - INSTALLATION) (5) Install the upper radiator mounts to the crossmember bolts, if removed. Tighten to 8 N·m (70 in. lbs.). (6) Install the radiator upper hose to the support clip (2.4L engine). HOSE CLAMPS DESCRIPTION - HOSE CLAMPS The cooling system uses spring type hose clamps. If a spring type clamp replacement is necessary, Fig. 24 Hose Clamp Tool 1 - HOSE CLAMP TOOL 6094 2 - HOSE CLAMP ENGINE RG RADIATOR FAN RELAY DESCRIPTION The low and high speed fan relays are mounted to the upper radiator support above the charge air cooler (Fig. 25). 7a - 29 (1) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (2) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (3) Remove upper radiator hose (Fig. 26). REMOVAL - LOWER RADIATOR HOSE WARNING: THE WARNING WORDS “DO NOT OPEN HOT” ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. (1) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (2) Remove lower radiator hose (Fig. 26). Fig. 25 RELAY LOCATIONS 1 2 3 4 5 6 - GLOW PLUG RELAY UPPER RADIATOR SUPPORT CHARGE AIR COOLER OUTLET HOSE RADIATOR FAN RELAYS UPPER RADIATOR HOSE EGR SOLENOID OPERATION The cooling system uses two fans. Both fans operate at two different speeds, low and high. Depending on engine coolant temperature and A/C system high side pressure, the fans operate at either low or high. The ignition switch supplies voltage to the coil side of the relay. When the ECM grounds the coil side of the relay, the contacts close and the battery supplies power to the fans. COOLANT SYSTEM HOSES REMOVAL REMOVAL - UPPER RADIATOR HOSE WARNING: THE WARNING WORDS “DO NOT OPEN HOT” ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. Fig. 26 UPPER AND LOWER RADIATOR HOSES 1 2 3 4 5 6 7 - COOLANT BYPASS HOSE RADIATOR ASSEMBLY UPPER RADIATOR HOSE COOLING FAN LOWER RADIATOR HOSE CHARGE AIR COOLER RADIATOR BRACKET 7a - 30 ENGINE RG COOLANT SYSTEM HOSES (Continued) REMOVAL - COOLANT BYPASS HOSE WARNING: THE WARNING WORDS “DO NOT OPEN HOT” ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. (1) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (2) Remove the coolant bypass hose (Fig. 26). INSTALLATION INSTALLATION - UPPER RADIATOR HOSE (1) Install upper radiator hose (Fig. 26). (2) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (3) Install engine cover (Refer to 9 - ENGINE INSTALLATION). INSTALLATION - LOWER RADIATOR HOSE (1) Install lower radiator hose (Fig. 26). (2) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). INSTALLATION - COOLANT BYPASS HOSE (1) Install cooling system bypass hose (Fig. 26). (2) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). EXHAUST SYSTEM RS 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page EXHAUST SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - EXCESSIVE EXHAUST SYSTEM NOISE . . . . . . . . . . DIAGNOSIS AND TESTING - EXHAUST SYSTEM RESTRICTION CHECK . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS EXHAUST SYSTEM . . . . . . . . . . . . . . . . CATALYTIC CONVERTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . .....1 .....2 .....2 .....2 .....3 .....3 .....3 .....4 .....4 .....4 EXHAUST SYSTEM DESCRIPTION The exhaust system consists of a catalytic converter, muffler, and a resonator with connecting pipes in-between (Fig. 1). The system is serviced in two sections; the catalytic converter and pipe, and the muffler and resonator with connecting pipe. A band clamp is used page REMOVAL .... INSPECTION . . INSTALLATION . CROSS-OVER PIPE REMOVAL .... INSTALLATION . HEAT SHIELDS DESCRIPTION . OPERATION . . . REMOVAL .... INSTALLATION . MUFFLER REMOVAL .... INSTALLATION . RESONATOR REMOVAL .... INSTALLATION . ........ ........ ........ - 3.3/3.8L ........ ........ .................5 .................6 .................6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 .7 .7 .7 .........................7 .........................8 .........................9 .........................9 to connect the joint between the two components. Three support hanger rods with rubber isolators are used to support and isolate the exhaust system. A flexible joint, integral to the catalytic converter, allows for engine movement. On vehicles equipped with AWD, an additional heat shield is mounted to the catalytic converter. The exhaust system is tuned for each vehicle/ powertrain combination. Fig. 1 Exhaust System - Typical (All Vehicles) 1 - CATALYTIC CONVERTER 2 - BAND CLAMP 3 - SUPPORTS - MUFFLER . . . . .................6 .................6 4 - SUPPORT - RESONATOR 5 - RESONATOR 6 - MUFFLER 11 - 2 EXHAUST SYSTEM RS EXHAUST SYSTEM (Continued) OPERATION The exhaust system contains, quiets, and cleans the exhaust gases generated by the engine. DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - EXCESSIVE EXHAUST SYSTEM NOISE CONDITION EXCESSIVE EXHAUST NOISE (UNDER HOOD) EXCESSIVE EXHAUST NOISE POSSIBLE CAUSES CORRECTION 1. Exhaust manifold cracked or broken. 1. Replace manifold. 2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace gasket. 3. EGR Valve to manifold gasket leakage. 3. Tighten fasteners or replace gasket. 4. EGR Valve to EGR tube gasket leakage. 4. Tighten fasteners or replace gasket. 5. EGR tube to manifold tube leakage. 5. Tighten tube nut. 6. Exhaust flex-joint to manifold leak. 6. Tighten joint fasteners and/or replace gasket. 7. Exhaust flex-joint. 7. Replace catalytic converter assembly. 8. Pipe and shell noise from front exhaust pipe. 8. Characteristic of single wall pipe. 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints. 2. Burned or rusted out muffler assembly or exhaust pipe. 2. Replace muffler resonator tailpipe assembly or exhaust pipe with catalytic converter assembly. 3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe assembly. 4. Restriction in exhaust system. 4. Perform Exhaust System Restriction Check. Replace component as necessary. 5. Converter material in muffler. 5. Replace muffler and converter assemblies. Check fuel injection and ignition systems for proper operation. DIAGNOSIS AND TESTING - EXHAUST SYSTEM RESTRICTION CHECK Exhaust system restriction can be checked by measuring back pressure using the DRB IIIt and PEP module pressure tester. 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. EXHAUST SYSTEM RS 11 - 3 EXHAUST SYSTEM (Continued) (1) Disconnect and remove the upstream (before catalytic converter) oxygen sensor. (Refer to 14 FUEL SYSTEM/FUEL INJECTION/O2 SENSOR REMOVAL) (2) Install the Exhaust Back Pressure Fitting Adaptor CH8519. (3) Connect the Low Pressure Sensor (15 psi) CH7063 to the back pressure fitting. (4) Following the PEP module instruction manual, connect all required cables to the DRB IIIt and PEP module. Select the available menu options on the DRBIIIt display screen for using the digital pressure gauge function. (5) Apply the park brake and start the engine. (6) With transmission in Park or Neutral, raise engine speed to 2000 RPM. Monitor the pressure readings on the DRBIIIt. Back pressure should not exceed specified limit. Refer to specification in table below EXHAUST BACK PRESSURE LIMITS . hanger brackets. Replace or tighten as necessary. It is important that exhaust system clearances and alignment be maintained. Perform the following procedures to align the exhaust system: (1) Loosen band clamp at catalytic converter pipe to muffler/resonator assembly. (2) Align the exhaust system by inserting pipe inward or outward until specification is achieved as shown in (Fig. 2). (3) Tighten band clamp to 54 N·m (40 ft. lbs.). NOTE: For applications with dual catalytic converters, repeat test on opposite converter using the previous steps. (7) If pressure exceeds maximum limits, inspect exhaust system for restricted component. For further catalytic converter inspection procedures, (Refer to 11 - EXHAUST SYSTEM/CATALYTIC CONVERTER INSPECTION). Replace component(s) as necessary. EXHAUST BACK PRESSURE LIMITS Fig. 2 Exhaust System Alignment Exhaust Back Pressure Limit (Max) Vehicle in Park/Neutral (no load) RPM 3.45 Kpa (0.5 psi) INSPECTION Inspect the exhaust pipes, catalytic converters, muffler, and resonators for cracked joints, broken welds and corrosion damage that would result in a leaking exhaust system. Inspect the clamps, support brackets, and insulators for cracks and corrosion damage. 1 2 3 4 - HANGER BRACKET TO BODY ISOLATOR HANGER - MUFFLER/RESONATOR SUPPORT 6 mm (0.25 in.) SPECIFICATIONS TORQUE N·m Ft. Lbs. In. Lbs. Band Clamp 54 40 — Cross-over Pipe—Fastener 41 30 — Exhaust Manifold Flange—Fastener 37 — 325 Heat Shield (Muffler)—Fastener 2.6 — 23 ADJUSTMENTS Heat Shield (Toe Board)—Fastener 2.6 — 23 A misaligned exhaust system is usually indicated by a vibration, rattling noise, or binding of exhaust system components. These noises are sometimes hard to distinguish from other chassis noises. Inspect exhaust system for broken, damaged or loose components such as; clamps, heat shields, isolators, and Heat Shield (Resonator Pipe)— Fastener 2.6 — 23 Insulator Mounting Bracket—Bolts 28 — 250 NOTE: Slip joint band clamps are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground off. DESCRIPTION 11 - 4 EXHAUST SYSTEM RS EXHAUST SYSTEM (Continued) SPECIAL TOOLS EXHAUST SYSTEM The exhaust flex-joint coupling (Fig. 3) is used to secure the catalytic converter to the exhaust manifold. The flex-joint has four bolts, four flag nuts and a gasket that are separate parts from the exhaust flex-joint. The flex-joint is welded to the catalytic converter. CAUTION: When servicing, care must be exercised not to dent or bend the bellows or bellows cover of the flex-joint. Should this occur, the flex-joint will eventually fail and require the catalytic converter be replaced. Back Pressure Test Adapter - CH8519 Pressure Transducer CH7063 Fig. 3 Flex-joint 1 2 3 4 - FLANGE END CAPS CATALYTIC CONVERTER FLEXIBLE BELLOWS OPERATION DRB III & PEP Module - OT-CH6010A CATALYTIC CONVERTER DESCRIPTION The toe board three-way catalytic converter is connected to the exhaust manifold by the use of flex joint and a gasket. The outlet connects to the muffler inlet pipe and is secured with a band type clamp (Fig. 1). 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 elemental Nitrogen (N) and water. 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 9punch through.9 EXHAUST SYSTEM RS 11 - 5 CATALYTIC CONVERTER (Continued) 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, if exhaust system is equipped with a catalytic converter. 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 backand-forth motion of a transverse mounted engine. Fig. 4 Downstream Oxygen Sensor 1 2 3 4 - OXYGEN SENSOR CONNECTOR CATALYTIC CONVERTER DOWNSTREAM OXYGEN SENSOR ENGINE HARNESS CONNECTOR 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. REMOVAL (1) Loosen clamp and disconnect the muffler/resonator assembly from catalytic converter pipe. (2) Disconnect downstream oxygen sensor electrical connector (Fig. 4). For removal of downstream oxygen sensor, (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR - REMOVAL). (3) Remove catalytic converter to exhaust manifold attaching fasteners (Fig. 5). (4) Remove catalytic converter and gasket (Fig. 5). Fig. 5 Catalytic Converter to Exhaust Manifold 1 2 3 4 - FLAG NUT GASKET BOLT CATALYTIC CONVERTER 11 - 6 EXHAUST SYSTEM RS CATALYTIC CONVERTER (Continued) INSPECTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. (5) Remove the upper right bank pipe connection fastener by accessing though the catalytic converter floor pan tunnel. (6) Lower the vehicle. (7) Remove the cross-over pipe (Fig. 6). (8) Remove gaskets and discard (Fig. 6). Check catalytic converter for a flow restriction. (Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS AND TESTING) Exhaust System Restriction Check for procedure. Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen sensor(s) and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate. NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic Information) for test procedures. INSTALLATION (1) Position new gasket onto the manifold flange and install catalytic converter (Fig. 5). Tighten fasteners to 37 N·m (325 in. lbs.). NOTE: Be careful not to twist or kink the oxygen sensor wires. (2) Install (if removed) and connect the downstream oxygen sensor (Fig. 4). (3) Install the muffler/resonator assembly. (Refer to 11 - EXHAUST SYSTEM/MUFFLER - INSTALLATION) CROSS-OVER PIPE - 3.3/3.8L REMOVAL (1) Disconnect negative cable from battery. (2) Remove the fasteners attaching the left bank manifold connection to cross-over pipe (Fig. 6). (3) Raise vehicle and remove the left front wheel. (4) Access the lower right bank pipe connection fastener through the left front wheel opening using a long ratchet extension. Loosen and remove the lower fastener. Fig. 6 CROSS-OVER PIPE 1 2 3 4 - CROSS-OVER PIPE BOLT GASKET FLAG NUT INSTALLATION (1) Position cross-over pipe to the manifold connections (Fig. 6). (2) Position new gasket on left bank (front) pipe connection and loosely install fasteners (Fig. 6). (3) Raise the vehicle. (4) Position new gasket on the right bank pipe connection and install fasteners. (5) Tighten right bank upper fastener to 41 N·m (30 ft. lbs.). (6) Tighten right bank lower fastener to 41 N·m (30 ft. lbs.) using a long ratchet extension accessing through the left wheel opening. (7) Install the left front wheel and lower vehicle. (8) Tighten the left bank pipe connection fasteners to 41 N·m (30 ft. lbs.) (Fig. 6). HEAT SHIELDS DESCRIPTION The exhaust system heat shields (Fig. 7), (Fig. 8), or (Fig. 9) are attached to the under body of the vehicle. On vehicles equipped with All Wheel Dive (AWD), an additional heat shield is mounted to the catalytic converter. EXHAUST SYSTEM RS 11 - 7 HEAT SHIELDS (Continued) Fig. 9 RESONATOR PIPE HEAT SHIELD Fig. 7 CATALYTIC CONVERTER HEAT SHIELD 1 - HEAT SHIELD - CATALYTIC CONVERTER 2 - SCREW (QTY. 4) 1 - SCREW (QTY. 3) 2 - HEAT SHIELD - RESONATOR PIPE 3 - MUFFLER REMOVAL (1) Raise vehicle on hoist. (2) Remove fasteners attaching applicable heat shield (Fig. 7), (Fig. 8), or (Fig. 9). (3) Remove heat shield(s). INSTALLATION (1) Position heat shield(s) to underbody. (2) Install heat shield fasteners and tighten to 2.6 N·m (23 in. lbs.) (Fig. 7), (Fig. 8), or (Fig. 9). (3) Lower vehicle. MUFFLER REMOVAL Fig. 8 MUFFLER HEAT SHIELD 1 - HEAT SHIELD - MUFFLER 2 - SCREW (QTY. 6) OPERATION Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed near the catalytic converter. Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped. Light over spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. (1) Raise vehicle on a body contact type hoist. NOTE: To provide removal clearance between muffler/resonator pipe and rear axle parts, the rear suspension must be relieved of all body weight. (2) Apply a penetrating oil to clamp nuts of component requiring removal. CAUTION: When servicing the exhaust system, care must be exercised not to dent or bend the bellows of the flex-joint. Should this occur, the flex-joint will eventually fail, requiring replacement of the catalytic converter. (3) Disconnect the right side axle half shaft from the rear differential module (AWD equipped only). 11 - 8 EXHAUST SYSTEM RS MUFFLER (Continued) Fig. 10 Exhaust System - Typical (All Vehicles) 1 - SCREW - RESONATOR HANGER TO BODY 2 - SCREW - MUFFLER HANGER TO BODY (4) Loosen the band clamp (Fig. 10) at the muffler to converter pipe connection. (5) Remove the exhaust hangers to body screws (Fig. 10). (6) Separate muffler pipe from converter pipe. (7) Remove muffler/resonator assembly by moving assembly forward and guiding the resonator through the rear axle to body opening. (8) Clean ends of pipes or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. When replacement is required on any component of the exhaust system, it is important that original equipment parts (or equivalent) be used for the following conditions: • Ensure proper alignment with other components in the system. • Provide acceptable exhaust noise levels. • Provide proper exhaust system back pressure for maintaining emission and performance levels. 3 - MUFFLER & RESONATOR ASSEMBLY 4 - CATALYTIC CONVERTER PIPE (4) Insert muffler pipe into catalytic converter pipe until the hangers are positioned as shown in (Fig. 11) INSTALLATION (1) Install the muffler/resonator assembly by guiding resonator between the rear axle and body. (2) Connect the muffler pipe to the converter pipe but do not tighten band clamp (Fig. 10). (3) Position hangers to body and install screws starting at the resonator working forward (Fig. 10). Tighten hanger screws to 28 N·m (250 in. lbs.). Fig. 11 Exhaust System Alignment 1 2 3 4 - HANGER BRACKET TO BODY ISOLATOR HANGER - MUFFLER/RESONATOR SUPPORT 6 mm (0.25 in.) EXHAUST SYSTEM RS 11 - 9 MUFFLER (Continued) 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. To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks. Clean remaining spot weld from the pipe using a file or grinder until surface is smooth. NOTE: Maintain proper clamp orientation when replacing with new clamp. (5) Tighten the band clamp to 55 N·m (40 ft. lbs.) (Fig. 12). (6) Connect the right side half shaft to the rear differential module (AWD equipped only). Fig. 12 Band Clamp 1 - BAND CLAMP 2 - TORQUE SPECIFICATION RESONATOR REMOVAL (1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER REMOVAL) INSTALLATION (1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER INSTALLATION) EXHAUST SYSTEM AND TURBOCHARGER RG 11a - 1 EXHAUST SYSTEM AND TURBOCHARGER TABLE OF CONTENTS page EXHAUST SYSTEM AND TURBOCHARGER DESCRIPTION . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS - TORQUE . . . . . . . . . TURBOCHARGER SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . TURBOCHARGER REMOVAL ....................... ......1 ......1 ......2 ......2 page CLEANING . . INSTALLATION HEAT SHIELDS REMOVAL .. INSTALLATION ...........................5 ..........................5 ...........................5 ..........................6 ......4 EXHAUST SYSTEM AND TURBOCHARGER DESCRIPTION The basic exhaust system consists of an engine exhaust manifold, turbocharger, exhaust down pipe, exhaust pipe, exhaust heat shield(s), muffler and exhaust tailpipe The exhaust system uses a single muffler. The exhaust system must be properly aligned to prevent stress, leakage and body contact. If the system contacts any body panel, it will transfer objectionable noises originating from the engine to the body. When inspecting an exhaust system, critically inspect for cracked or loose joints, stripped screw or bolt threads, corrosion damage and worn, cracked or broken hangers. Replace all components that are badly corroded or damaged. DO NOT attempt to repair. When replacement is required, use original equipment parts (or equivalent). This will assure proper alignment and provide acceptable exhaust noise levels. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes. SPECIFICATIONS - TORQUE 2.5L DIESEL - TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Exhaust Manifold Nuts 32.4 24 — Exhaust Manifold Heat shield Bolts 27.5 21 — Turbocharger Bracket Bolts 47.1 35 — Turbocharger Downpipe Nuts 32.4 24 — Turbocharger Oil Feed Line Fitting 24.5 18 215 Turbocharger to Exhaust Manifold Nuts 32.4 24 — 11a - 2 EXHAUST SYSTEM AND TURBOCHARGER RG TURBOCHARGER SYSTEM DESCRIPTION CAUTION: The turbocharger is a performance part and must not be tampered with. The wastegate bracket is an integral part of the turbocharger. Tampering with the wastegate components can reduce durability by increasing cylinder pressure and thermal loading due to incorrect inlet and exhaust manifold pressure. Poor fuel economy and failure to meet regulatory emissions laws may result. Increasing the turbocharger boost WILL NOT increase engine power. The turbocharger is an exhaust-driven supercharger which increases the pressure and density of the air entering the engine. With the increase of air entering the engine, more fuel can be injected into the cylinders, which creates more power during combustion. The turbocharger assembly consists of four (4) major component systems (Fig. 1) (Fig. 2): • Turbine section • Compressor section • Bearing housing • Wastegate Fig. 2 Turbocharger Wastegate Actuator 1 - TURBOCHARGER 2 - DIAPHRAGM 3 - WASTE GATE ACTUATOR OPERATION Fig. 1 Turbocharger Operation 1 2 3 4 5 6 7 8 - TURBINE SECTION EXHAUST GAS BEARING HOUSING COMPRESSOR SECTION INLET AIR COMPRESSED AIR TO ENGINE EXHAUST GAS EXHAUST GAS TO EXHAUST PIPE Exhaust gas pressure and energy drive the turbine, which in turn drives a centrifugal compressor that compresses the inlet air, and forces the air into the engine through the charge air cooler and plumbing. Since heat is a by-product of this compression, the air must pass through a charge air cooler to cool the incoming air and maintain power and efficiency. Increasing air flow to the engine provides: • Improved engine performance • Lower exhaust smoke density • Improved operating economy • Altitude compensation • Noise reduction. The turbocharger also uses a wastegate (Fig. 3), which regulates intake manifold air pressure and prevents over boosting at high engine speeds. When the wastegate valve is closed, all of the exhaust gases flow through the turbine wheel. As the intake manifold pressure increases, the wastegate actuator opens the valve, diverting some of the exhaust gases away from the turbine wheel. This limits turbine shaft speed and air output from the impeller. The turbocharger is lubricated by engine oil that is pressurized, cooled, and filtered. The oil is delivered to the turbocharger by a supply line that is tapped into the oil filter head. The oil travels into the bearing housing, where it lubricates the shaft and bearings (Fig. 4). A return pipe at the bottom of the EXHAUST SYSTEM AND TURBOCHARGER RG 11a - 3 TURBOCHARGER SYSTEM (Continued) Fig. 4 Turbocharger Oil Supply and Drain 1 - BEARINGS 2 - OIL SUPPLY (FROM ENGINE BLOCK) 3 - OIL RETURN (TO OIL PAN) Fig. 3 Wastegate Operation 1 - SIGNAL LINE 2 - EXHAUST BYPASS VALVE 3 - WASTEGATE 4 - EXHAUST 5 - TURBINE 6 - EXHAUST BYPASS VALVE 7 - WASTEGATE 8 - EXHAUST 9 - TURBINE 10 - SIGNAL LINE bearing housing, routes the engine oil back to the crankcase. The most common turbocharger failure is bearing failure related to repeated hot shutdowns with inadequate “cool-down” periods. A sudden engine shut down after prolonged operation will result in the transfer of heat from the turbine section of the turbocharger to the bearing housing. This causes the oil to overheat and break down, which causes bearing and shaft damage the next time the vehicle is started. Letting the engine idle after extended operation allows the turbine housing to cool to normal operating temperature. The following chart should be used as a guide in determining the amount of engine idle time required to sufficiently cool down the turbocharger before shut down, depending upon the type of driving and the amount of cargo. TURBOCHARGER (COOL DOWN( CHART Driving Load Condition Turbocharger Idle Time (in minuetes) Temperature Before Shut Down Stop & Go Empty Cool Less than 1 Stop & Go Medium Warm 1 Highway Speeds Medium Warm 2 City Traffic Max. GCWR Warm 3 Highway Speeds Max. GCWR Warm 4 Uphill Grade Max. GCWR Hot 5 11a - 4 EXHAUST SYSTEM AND TURBOCHARGER TURBOCHARGER REMOVAL The exhaust manifold and turbocharger cannot be remove with the engine in vehicle. (1) Remove engine from vehicle and mount on engine stand (Refer to 9 - ENGINE - REMOVAL). (2) Remove thermostat to upper radiator hose pipe (Fig. 5). RG (3) (4) (5) lines (6) 6). (7) from Remove engine lift hook (Fig. 6). Remove exhaust manifold heat shield (Fig. 6). Disconnect turbocharger oil supply and return at turbocharger (Fig. 6). Remove exhaust manifold retaining nuts (Fig. Remove exhaust manifold and turbocharger engine (Fig. 6). Fig. 6 EXHAUST MANIFOLD AND TURBOCHARGER Fig. 5 TURBOCHARGER AND COOLANT PIPES 1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT 2 - TURBOCHARGER OUTLET PIPE 3 - ADAPTER HOSE 4 - HEAT SHIELD 5 - HOSE CLAMPS 6 - TURBOCHARGER INLET PIPE RETAINING BOLT 7 - TURBOCHARGER INLET PIPE 8 - ADAPTER HOSE 9 - HOSE CLAMPS 10 - CLAMP 11 - EGR VALVE TO INTAKE AIR INLET PIPE 12 - CLAMP 13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE 1 - TURBOCHARGER OIL SUPPLY BANJO BOLT 2 - COPPER WASHER 3 - EXHAUST MANIFOLD GASKET 4 - COPPER WASHER 5 - EXHAUST MANIFOL HEAT SHIEL RETAINING BOLT 6 - TURBOCHARGER 7 - ENGINE LIFT HOOK 8 - ENGINE LIFT HOOK RETAINING BOLT 9 - SPACER 10 - EXHAUST MANIFOLD RETAINING NUT 11 - TURBOCHARGER OIL RETURN HOSE 12 - HOSE CLAMPS 13 - EXHAUST MANIFOLD STUDS RG EXHAUST SYSTEM AND TURBOCHARGER 11a - 5 TURBOCHARGER (Continued) (8) With exhaust manifold and turbocharger assembly on work bench, remove turbocharger to exhaust manifold retaining bolts. Separate exhaust manifold and turbocharger. CLEANING All old gaskets should be inspected for any tears or signs of prior leakage. If any gaskets show such indications, they should be replaced with new gaskets. All gasket mating surfaces must be cleaned of old gasket material to produce a smooth and dirt free sealing surface for the new gasket. INSTALLATION (1) Connect exhaust manifold and turbocharger. Torque nuts to 32.4N·m. (2) Position new exhaust manifol gasket on exhaust manifol studs (Fig. 6). (3) Install exhaust manifold and turbocharger on engine (Fig. 6). Torque nuts to 32.4N·m. (4) Connect turbocharger oil supply and return lines at turbocharger (Fig. 6). Torque oil supply line to 24.5N·m. (5) Install exhaust manifold shield (Fig. 6). Torque bolts to 27.5N·m. (6) Install engine lift hook (Fig. 6). Torque bolts to 32.4N·m. (7) Install thermostat to upper radiator hose tube and turbocharger outlet tube (Fig. 5). (8) Install engine in vehicle (Refer to 9 - ENGINE - INSTALLATION). Fig. 7 TURBOCHARGER AND COOLANT PIPES HEAT SHIELDS REMOVAL (1) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (2) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (3) Partially drain cooling system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE). (4) Remove thermostat housing to upper radiator hose tube (Fig. 7). (5) Remove exhaust manifold heat shield retaining bolts and remove shield (Fig. 8). 1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT 2 - TURBOCHARGER OUTLET PIPE 3 - ADAPTER HOSE 4 - HEAT SHIELD 5 - HOSE CLAMPS 6 - TURBOCHARGER INLET PIPE RETAINING BOLT 7 - TURBOCHARGER INLET PIPE 8 - ADAPTER HOSE 9 - HOSE CLAMPS 10 - CLAMP 11 - EGR VALVE TO INTAKE AIR INLET PIPE 12 - CLAMP 13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE 11a - 6 EXHAUST SYSTEM AND TURBOCHARGER RG HEAT SHIELDS (Continued) INSTALLATION (1) Reposition exhaust heat shield (Fig. 8). (2) Install exhaust heat shield retaining bolts (Fig. 8). Torque bolts to 27.5N·m. (3) Install thermostat housing to upper radiator hose tube (Fig. 7). (4) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (5) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (6) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). Fig. 8 EXHAUST MANIFOLD AND TURBOCHARGER 1 - TURBOCHARGER OIL SUPPLY BANJO BOLT 2 - COPPER WASHER 3 - EXHAUST MANIFOLD GASKET 4 - COPPER WASHER 5 - EXHAUST MANIFOL HEAT SHIEL RETAINING BOLT 6 - TURBOCHARGER 7 - ENGINE LIFT HOOK 8 - ENGINE LIFT HOOK RETAINING BOLT 9 - SPACER 10 - EXHAUST MANIFOLD RETAINING NUT 11 - TURBOCHARGER OIL RETURN HOSE 12 - HOSE CLAMPS 13 - EXHAUST MANIFOLD STUDS FRAME & BUMPERS RS 13 - 1 FRAME & BUMPERS TABLE OF CONTENTS page BUMPERS SPECIFICATIONS - TORQUE . . . FRONT FASCIA REMOVAL ................. INSTALLATION . . . . . . . . . . . . . . FRONT BUMPER REINFORCEMENT REMOVAL ................. INSTALLATION . . . . . . . . . . . . . . REAR FASCIA REMOVAL ................. INSTALLATION . . . . . . . . . . . . . . REAR BUMPER REINFORCEMENT REMOVAL ................. INSTALLATION . . . . . . . . . . . . . . REAR FASCIA - SCUFF PAD REMOVAL ................. ............1 ............1 ............1 ............2 ............2 ............3 ............3 ............3 ............3 ............4 page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRAME SPECIFICATIONS FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS - TORQUE . . . . . . . . . . . . . 9 FRONT CRADLE CROSSMEMBER DESCRIPTION DESCRIPTION - FRONT CRADLE CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION - FRONT CRADLE CROSSMEMBER THREAD REPAIR . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 FRONT CROSSMEMBER MOUNT BUSHINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 BUMPERS SPECIFICATIONS - TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Front bumper reinforcement attaching nut 54 40 — Rear bumper reinforcement attaching nut 27 20 — FRONT FASCIA REMOVAL (1) Release hood latch and open hood. (2) Remove the headlamp assemblies (Refer to 8 ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ HEADLAMP - REMOVAL). (3) Hoist vehicle and support with safety stands. (4) Remove the five bolts attaching bottom of fascia/air dam to radiator closure panel. (5) Remove front wheels. (6) Remove front wheelhouse splash shields fasteners as necessary to gain access to bolts attaching front fascia to fender. (Refer to 23 - BODY/EXTERIOR/ WHEELHOUSE SPLASH SHIELD - REMOVAL). (7) Remove the two bolts and two nuts attaching fascia to the front fenders (Fig. 1). (8) Disconnect fog lamp wire connectors, if necessary. (9) Lower vehicle. (10) Remove two bolts attaching the upper grille support to the headlamp mounting panel at each side of the grille. (11) Remove bumper fascia from vehicle. INSTALLATION (1) Position front bumper fascia on vehicle. (2) Install the two bolts attaching fascia to headlamp mounting panel at each side of grille. (3) Hoist vehicle and support with safety stands. (4) Install the two bolts and two nuts attaching fascia to the front fenders (Fig. 1). The fascia should be flush to fender. (5) Install front wheelhouse splash shields fasteners. (Refer to 23 - BODY/EXTERIOR/ WHEELHOUSE SPLASH SHIELD - INSTALLATION). (6) Install front wheels. (7) Connect fog lamp wire connectors, if necessary. (8) Install the five bolts attaching bottom of fascia to radiator closure panel. (9) Lower the vehicle. 13 - 2 FRAME & BUMPERS RS FRONT FASCIA (Continued) Fig. 1 FRONT BUMPER FASCIA 1 - FRONT BUMPER FASCIA 2 - FRONT BUMPER REINFORCEMENT 3 - RADIATOR ENCLOSURE (10) Install the headlamp assemblies. (Refer to 8 ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ HEADLAMP - INSTALLATION). FRONT BUMPER REINFORCEMENT REMOVAL (1) Remove front bumper fascia. (Refer to 13 FRAMES & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL) (2) Support front bumper reinforcement on a suitable lifting device. (3) Remove the four nuts attaching front bumper reinforcement to frame rail (Fig. 2). (4) Remove front bumper reinforcement from vehicle. Fig. 2 FRT BUMPER REINFORCEMENT 1 - FRONT BUMPER REINFORCEMENT 2 - FRAME RAILS INSTALLATION NOTE: Check position of the arrows molded into the foam for correct orientation. (1) Support front bumper reinforcement using a suitable lifting device and lift into position. (2) Install the four nuts attaching reinforcement to frame rails. Tighten nuts to 54 N·m (40 ft. lbs.) torque. (3) Install front fascia. (Refer to 13 - FRAMES & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION). FRAME & BUMPERS RS REAR FASCIA REMOVAL (1) Open liftgate. (2) Remove the two screws attaching the upper fascia to the fascia support. (3) Hoist and support vehicle with safety stands. (4) Remove the six screws attaching rear fascia to rear fascia brackets (Fig. 3). (5) Remove the four plastic push pin attaching bottom of rear fascia to fascia support. (6) Remove rear fascia from vehicle by lifting sides of fascia up and outboard to release from rear fascia brackets. 13 - 3 (5) Install the six screws attaching rear fascia to rear fascia brackets. (6) Install the four plastic push pins attaching bottom of rear fascia to fascia support. (7) Lower vehicle. (8) Install the two screws attaching the upper fascia to the fascia support. REAR BUMPER REINFORCEMENT REMOVAL (1) Remove rear bumper fascia. (Refer to 13 FRAMES & BUMPERS/BUMPERS/REAR FASCIA REMOVAL) (2) Support rear bumper reinforcement on a suitable lifting device. (3) Remove the six nuts attaching rear bumper reinforcement to frame rail extensions (Fig. 4). (4) Remove rear bumper reinforcement from vehicle. Fig. 3 REAR BUMPER FASCIA 1 2 3 2 - REAR PUSH REAR REAR FASCIA PINS BUMPER REINFORCEMENT FASCIA BRACKET INSTALLATION (1) Hoist and support vehicle with safety stands. (2) Position rear fascia on vehicle. (3) Engage front edge of fascia under the fascia support flange. (4) Engage sides of fascia to top and front edge of the rear fascia brackets. NOTE: Verify fascia is still engaged under the liftgate. Ensure acceptable and consistent gap between liftgate and fascia. Fig. 4 REAR BUMPER REINFORCEMENT 1 - REAR BUMPER REINFORCEMENT 2 - FRAME RAIL EXTENSIONS 3 - NUTS INSTALLATION (1) Support rear bumper reinforcement using a suitable lifting device to lift into position. (2) Position rear bumper reinforcement on vehicle. 13 - 4 FRAME & BUMPERS RS REAR BUMPER REINFORCEMENT (Continued) (3) Install the six nuts attaching rear bumper reinforcement to frame rail extensions and tighten to 27 N·m (20 ft. lbs.) torque (Fig. 4). (4) Install rear bumper fascia. (Refer to 13 FRAMES & BUMPERS/BUMPERS/REAR FASCIA INSTALLATION). REAR FASCIA - SCUFF PAD REMOVAL The scuff pad may not be salvageable during the removal process. The scuff pad should be replaced if damaged or broken. Check availability before servicing. The scuff pad serviceability is improved if the rear fascia is to be removed for service. NOTE: If the rear fascia is to be removed for other service issues or If the scuff pad is to be reused use the steps below. Fig. 5 SCUFF PAD 1 - SCUFF PAD 2 - TABS (1) Remove rear bumper fascia.(Refer to 13 FRAMES & BUMPERS/BUMPERS/REAR FASCIA REMOVAL) (2) Using a trim stick, pry up the rear edge of the scuff pad while squeezing the rear locking tabs from underneath the fascia to release the rear edge of scuff pad from the rear bumper fascia. Pull the scuff pad up and squeeze the remaining tabs to release the remaining of the scuff pad. (Fig. 5). FRAME NOTE: If the rear fascia is to not to be removed for other service issues use the step below. SPECIFICATIONS (3) Using a trim stick, pry up the rear edge of the scuff pad to release tabs from the rear bumper fascia and pull scuff pad to release the forward tabs (Fig. 5). INSTALLATION (1) (2) (3) (4) slots, (5) cia. Verify that there are fifteen slots in the fascia. Place scuff pad in position (Fig. 5). Align and insert the center forward tab. Align the remaining tabs and press into the starting in the center and working outboard. Assure all tabs are fully engaged into the fas- (6) If rear bumper fascia has been removed install. (Refer to 13 - FRAME & BUMPERS/BUMPERS/ REAR FASCIA - INSTALLATION). FRAME DIMENSIONS Frame dimensions are listed in metric scale. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location. VEHICLE PREPARATION Position the vehicle on a frame alignment rack, refer to instructions provided with equipment being used. Adjust the vehicle PLP heights to the specified dimension above the work surface (datum line). Vertical dimensions can be taken from the datum line to the locations indicated were applicable. INDEX DESCRIPTION FIGURE CROSSMEMBER DIMENSIONS 6 ENGINE BOX - TOP VIEW 7 ENGINE COMPARTMENT AND FRAME RAIL - SIDE VIEW 8 FULL VEHICLE - BOTTOM VIEW 9 FRAME & BUMPERS RS FRAME (Continued) Fig. 6 CROSSMEMBER DIMENSIONS 13 - 5 13 - 6 FRAME & BUMPERS RS Fig. 7 ENGINE BOX - TOP VIEW FRAME (Continued) FRAME & BUMPERS Fig. 8 ENGINE COMPARTMENT AND FRAME RAIL - SIDE VIEW RS 13 - 7 FRAME (Continued) 13 - 8 FRAME & BUMPERS RS FRAME (Continued) Fig. 9 FULL VEHICLE - BOTTOM VIEW FRAME & BUMPERS RS 13 - 9 FRAME (Continued) SPECIFICATIONS - TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Front Cradle Crossmember to Fram Rail Attaching Bolts (4) 163 120 — Reinforcement Plate to Crossmember Attaching Bolt Size M14 (9) 153 113 — Reinforcement Plate to Crossmember Attaching Bolt Size M12 (1) 106 78 — Reinforcement Plate to Crossmember Attaching Bolt Size M10 (4) 61 45 — Rear Engine Mount to Crossmember Attaching Through Bolt 68 50 — Radiator Support Crossmember Attaching Bolts 51 38 — FRONT CRADLE CROSSMEMBER DESCRIPTION DESCRIPTION - FRONT CRADLE CROSSMEMBER This vehicle uses a one piece cast aluminum cradle for the front cradle crossmember. The cradle crossmember is used as the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has the power steering hoses and the chassis brake tubes attached to it. WARNING: If a threaded hole in the suspension cradle needs to be repaired, only use the type of thread insert and installation procedure specified for this application. The threaded holes in the front cradle crossmember that are used for attachment of the lower control arm rear bushing retainer, power steering hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coilt thread insert which has been specifically developed for this application. Refer to the Mopar Parts Catalog for the specified Heli-Coilt thread insert to be used for this application. The procedure for installing the HeliCoilt thread insert is detailed in the Service Procedures section in this group of the service manual. DESCRIPTION - FRONT CRADLE CROSSMEMBER THREAD REPAIR WARNING: When performing this procedure use only the thread inserts which are specified in the Mopar Parts Catalog for this repair procedure. These thread inserts have been specifically developed for this application and use of other types of thread inserts can result in an inferior long term repair. The threaded holes in the front cradle crossmember, if damaged, can repaired by installing a HeliCoilt thread insert. The threaded holes that are repairable using the thread insert, are the lower control arm rear bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering hoses, and brake hose attachment holes. This repair procedure now allows the threaded holes in the cradle crossmember to be repaired, eliminating the need to replace the cradle crossmember if damage occurs to one of the threaded holes. The thread inserts for this application are specified by part number in the Mopar Parts Catalog. Do not use a substitute thread insert. The specific tools and equipment required to install the thread insert are listed below. Refer to the instructions included with the thread insert for the detailed procedure used for the installation of the thread insert. NOTE: The thread inserts for this application are for the repair of M8x1.25 and M10x1.5 threads. Be sure the correct tools are used for the required thread insert size. TOOL REQUIREMENT FOR M8x1.25 Thread • 8.3mm (5/16 in.) Drill Bit • 120° Countersink • Heli-Coilt Tap #4863-8 • Heli-Coilt Gage #4624-8 • Heli-Coilt Hand Inserting Tool 7751-8 • Needle Nose Pliers – For Removal Of Thread Insert Driving Tang TOOL REQUIREMENT FOR M10x1.5 Thread • 10.5mm (25/64 in.) Drill Bit • 120° Countersink • Heli-Coilt Tap #4863-10 • Heli-Coilt Gage #4624-10 • Heli-Coilt Hand Inserting Tool 7751-10 • Needle Nose Pliers – For Removal Of Thread Insert Driving Tang 13 - 10 FRAME & BUMPERS RS FRONT CRADLE CROSSMEMBER (Continued) REMOVAL The front cradle crossmember must be installed in the design location to achieve proper front end suspension alignment. If the cradle crossmember is removed without applying reference marks on the frame rails, align the cradle crossmember according to the dimensions provided in this group. NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement nut can be obtained through MoparT. REMOVAL (1) Disconnect battery negative cable. (2) Remove steering column lower cover from instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - REMOVAL). (3) Remove steering column cover backing plate (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN COVER BACKING PLATE - REMOVAL). (4) Position steering so front wheels are straight ahead. CAUTION: Do not rotate steering wheel after disengaging lower coupling from steering gear, damage to air bag clock spring can result. (6) Remove steering column coupling from telescoping steering gear shaft. (7) Hoist vehicle and support on safety stands. (8) Position a drain pan under power steering pump and oil return hose coupling. (9) Using a hose pinch-off pliers (C-4390), pinch power steering oil return hose off between the crossmember coupling and the pump. (10) Loosen hose clamp at the cradle crossmember coupling. (11) Disconnect return hose from metal tube. (12) While holding pressure relief valve nut on back of power steering pump, Remove flare nut attaching high pressure hose to back of pump. (13) Remove high pressure hose from pump. (14) Allow power steering fluid to drain into pan. (15) Remove bolts attaching anti-lock brake sensor leads to cradle crossmember. (16) Position anti-lock brake leads out of the way. (17) Disconnect stabilizer bar links from ends of stabilizer bar. (18) Disconnect lower ball joints from lower steering knuckles (Refer to 2 - SUSPENSION/FRONT/ LOWER BALL JOINT - REMOVAL). (19) Remove the rear engine mount heat shield (Fig. 11). (5) Remove clinch bolt attaching steering column coupling to steering gear shaft (Fig. 10). Fig. 11 REAR MOUNT HEAT SHIELD 1 2 3 4 - BOLT HEAT SHIELD CLIP REAR ENGINE MOUNT Fig. 10 STEERING COUPLING 1 2 3 4 5 6 - STEERING SHAFT BOOT STEERING SHAFT CROSSMEMBER STEERING GEAR MOUNT TRANSAXLE (20) Remove through bolt attaching rear engine mount to cradle crossmember (Fig. 12). (21) Using paint or grease pencil, mark outline of cradle crossmember on frame rails to aid installation. (22) Support cradle crossmember on suitable lifting device (Fig. 14). (23) Remove bolts attaching crossmember to front frame rails (Fig. 13). FRAME & BUMPERS RS 13 - 11 FRONT CRADLE CROSSMEMBER (Continued) (24) Remove cradle crossmember from vehicle (Fig. 14). Fig. 13 CRADLE CROSSMEMBER MOUNT Fig. 12 REAR MOUNT 1 2 3 4 - BOLT REAR MOUNT BRACKET THROUGH BOLT REAR MOUNT 1 2 3 4 5 - CROSSMEMBER MOUNT BRAKE HOSE MOUNT STEERING TIE ROD FRONT CROSSMEMBER FRAME RAIL Fig. 14 CRADLE CROSSMEMBER 1 - ENGINE OIL PAN 2 - TRANSAXLE 3 - LOWER CONTROL ARM 4 - FRONT CROSSMEMBER 5 - LIFT DEVICE 6 - SPINDLE 13 - 12 FRAME & BUMPERS RS FRONT CRADLE CROSSMEMBER (Continued) INSTALLATION NOTE: If cradle crossmember requires replacement. Refer to Group 2, Suspension, to transfer suspension components and Group 19, Steering, to transfer steering components. (1) Support crossmember on suitable lifting device (Fig. 14). (2) Position crossmember to vehicle. (3) Loosely install bolts attaching cradle crossmember to front frame rails. (4) Align crossmember to previously made marks on frame rails. (5) Tighten bolts attaching cradle crossmember to frame rails. (6) Install through bolt attaching rear engine mount to cradle crossmember (Fig. 12) and tighten to 68 N·m (50 ft. lbs.) torque. (7) Install the rear mount heat shield (Fig. 11). (8) Connect lower ball joints to steering knuckles (Refer to 2 - SUSPENSION/FRONT/LOWER BALL JOINT - INSTALLATION) (9) Connect stabilizer bar links to ends of stabilizer bar. (10) Install bolts attaching anti-lock brake sensor leads to cradle crossmember. (11) Install high pressure hose to pump. (12) Connect return hose to metal tube. (13) Tighten hose clamp at the cradle crossmember coupling. (14) Remove pinch-off pliers. (15) Position steering so front wheels are straight ahead. (16) Install steering column coupling to telescoping steering gear shaft. (17) Install clinch bolt attaching steering column coupling to steering gear shaft. (18) Install steering column cover backing plate (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN COVER BACKING PLATE INSTALLATION) (19) Install steering column lower cover from instrument panel (Refer to 23 - BODY/INSTRU- MENT PANEL/STEERING COLUMN COVER - INSTALLATION). (20) Connect battery negative cable. OPENING FRONT CROSSMEMBER MOUNT BUSHINGS REMOVAL (1) Using paint or grease pencil, mark outline of cradle crossmember on frame rails. (2) Loosen bolts attaching crossmember to frame rails. (3) Remove bolt on bushing that requires replacement. (4) Allow cradle crossmember to drop down enough to gain clearance for bushing removal. (5) Remove bushing from vehicle. INSTALLATION (1) Apply rubber lubrication or soap to replacement bushing. (2) Insert lower half of bushing into square hole in cradle crossmember. (3) Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. (4) Squeeze bushing halves together to ensure they are properly mated. (5) Lift cradle crossmember upward to close gap between the bushing and frame. (6) Verify that lower bushing is fully seated into cradle crossmember and upper bushing. (7) Install bolt attaching bushing and crossmember to frame rail hand tight. (8) Align cradle crossmember to reference marks on frame rails. (9) Tighten cradle crossmember to frame rails attaching bolts to 163 N·m (120 ft. lbs.) torque. HEATED SYSTEMS RS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 5 HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 7 HEATED GLASS TABLE OF CONTENTS page HEATED GLASS DESCRIPTION . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . DEFOGGER RELAY DESCRIPTION . . . . . . . . . . . . . REAR WINDOW DEFOGGER GRID STANDARD PROCEDURE - GRID REPAIR REAR . . . . . . . . . . . . .............1 .............2 .............2 LINE .............2 page REAR WINDOW DEFOGGER SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD GRID DIAGNOSIS AND TESTING - SYSTEM TEST STANDARD PROCEDURE - GRID LINE AND TERMINAL REPAIR . . . . . . . . . . . . . . . . . ....2 ....2 ...3 ....3 HEATED GLASS DESCRIPTION Fig. 2 (TYPICAL) Heated Windshield Wiper De-icer Fig. 1 REAR WINDOW DEFOGGER (TYPICAL) 1 - REAR DEFOGGER GRID 2 - REAR WINDOW 1 - DEFROSTER OUTLET 2 - VIN # 3 - HEATED WINDSHIELD GRID 8G - 2 HEATED GLASS RS HEATED GLASS (Continued) The electrically heated Rear Window Defogger (Fig. 1), Heated Power Side View Mirrors, and Heated Windshield Wiper De-icer (Fig. 2)is available on select models. OPERATION The Rear Window Defogger(Refer to 8 - ELECTRICAL/HEATED GLASS - DESCRIPTION) system consists of two vertical bus bars linked by a series of grid lines on the inside surface of the rear window. The electrical circuit consists of the rear defogger switch in the HVAC control assembly and a relay with timer switch to turn OFF the system after ten minutes. The main feed circuit is protected by fuse 13 (40 amp) in the Power Distribution Center (PDC) which is connected directly to the front control module (FCM) to form an integrated unit called an Integrated Power Module (IPM). The rear defogger switch and relay also activates the heated power side view mirrors. The rear defogger switch also activates the heated windshield wiper de-icer which is powered by the RUN/ACC relay in the IPM and feed thru fuse #11 (20 amp) in the PDC. The heated mirror circuit is protected by a non-servicable Positive Temperature Coefficient (PTC) located inside the PDC. The heated windshield wiper de-icer circuit is protected by fuse 11 (20 amp) in the PDC. The Heated Windshield Wiper Deicer is also activated when the DEFROST mode is selected on the HVAC. In the DEFROST mode the rear defogger timout is bypassed, the heated windshield wiper deicer will stay ON until the another mode is selected. For circuit information and component location refer to appropriate section for Wiring Diagrams. CAUTION: Since grid lines can be damaged or scraped off with sharp instruments, care should be taken in cleaning the glass or removing foreign materials, decals or stickers. Normal glass cleaning solvents or hot water used with rags or toweling is recommended. DEFOGGER RELAY DESCRIPTION There is no heated windshield wiper de-icer relay. The grid is powered directly from fuse #11 in the PDC and is controlled directly from the HVAC control assembly. REAR WINDOW DEFOGGER GRID STANDARD PROCEDURE - GRID LINE REPAIR REAR For Grid repair procedure for the rear window defogger (Refer to 8 - ELECTRICAL/HEATED GLASS/WINDSHIELD GRID - STANDARD PROCEDURE). REAR WINDOW DEFOGGER SWITCH DESCRIPTION Fig. 3 HVAC CONTROL PANEL 1 - TRIM BEZEL 2 - ACT SENSOR 3 - A/C REQUEST SWITCH 4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH COMBO 5 - FRONT WINDOW DEFROSTER MODE SELECTOR The rear window defogger switch is integrated into the HVAC control panel assembly (Fig. 3) OPERATION A LED indicator will illuminate when the switch is activated. The switch energizes the HVAC control assembly when it requests the Front Control Module (FCM) to activate the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger, heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. HEATED GLASS RS 8G - 3 WINDSHIELD GRID DIAGNOSIS AND TESTING - SYSTEM TEST Electrically heated rear window defogger or the heated windshield wiper deicer operation can be checked on the vehicle in the following manner: (1) Turn the ignition switch to the ON position. (2) Using a ammeter on the battery, turn the rear defogger control switch to the ON position, a distinct increase in amperage draw should be noted. (3) The rear window defogger or the heated windshield wiper deicer operation can be checked by feeling the glass. A distinct difference in temperature between the grid lines and adjacent clear glass can be detected in 3 to 4 minutes of operation. (4) Using a DC voltmeter (Fig. 4) contact terminal B with the negative lead, and terminal A with the positive lead. The voltmeter should read 10-14 volts. (5) Indicator light illumination means that there is power available at the switch only and does not necessarily verify system operation. (6) If turning the defogger switch ON, no distinct current draw on the ammeter the problem should be isolated in the following manner: • Confirm that ignition switch is ON. • Ensure that the heated rear window or the heated windshield wiper deicer feed pigtail is connected to the wiring harness and that the ground pigtail is in fact grounded. • Ensure that the proper fuse in the PDC is OK. (7) When the above steps have been completed and the system is still inoperative it may be necessary to connect a DRBIII scan tool and refer to the Diagnostic Service Manual, you may also check for the following being defective: • HVAC control assembly • Rear window defogger relay in the PDC portion of the IPM. • Rear window defogger relay control circuity in the FCM portion of the IPM. • Check for loose connector or a wire pushed out of connector. • Rear window or the windshield grid lines (all grid lines would have to be broken, or one of the feed pigtails not connected to the bus bar, for no ammeter deflection). (8) If turning the switch ON produces severe voltmeter deflection, the circuit should be closely checked for a shorting condition. (9) If the system operation has been verified but indicator LED does not light, replace the HVAC control assembly. (10) For detailed wiring information, refer to the appropriate section for Wiring Diagrams. Fig. 4 Grid Line Test 1 2 3 4 5 6 7 - VOLTMETER TERMINAL B FEED WIRE MID-POINT C (TYPICAL) HEATED REAR WINDOW GRIDS GROUND WIRE TERMINAL A STANDARD PROCEDURE - GRID LINE AND TERMINAL REPAIR WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION. CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, HARMFUL IF SWALLOWED. AVOID CONTACT WITH SKIN AND EYES. FOR SKIN, WASH AFFECTED AREAS WITH SOAP AND WATER. DO NOT TAKE INTERNALLY. IF TAKEN INTERNALLY, INDUCE VOMITING; CALL A PHYSICIAN IMMEDIATELY. IF IN CONTACT WITH EYES, FLUSH WITH PLENTY OF WATER. USE WITH ADEQUATE VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTENTS CONTAINS 3% FLAMMABLE SOLVENTS. KEEP OUT OF REACH OF CHILDREN. The repair for the front windshield or the rear window grids are the same. The repair of grid lines and replacement of the terminal is possible using the Mopart Repair Package or equivalent. (1) Clean area surrounding grid line or terminal by gently rubbing area with steel wool. (2) Wipe area with clean cloth soaked in alcohol or similar solvent. It is necessary that all contaminants be removed from repair area. (3) Remove package separator clamp and mix plastic conductive epoxy thoroughly. 8G - 4 HEATED GLASS RS WINDSHIELD GRID (Continued) (4) For grid line, mark off area to be repaired with masking tape (Fig. 5). (5) Apply conductive epoxy through slit in masking tape. Overlap both ends of the break. (6) For a terminal replacement, apply a thin layer of epoxy to area where terminal was fastened. (7) Apply a thin layer of epoxy on terminal and place terminal on desired location. To prevent terminal from falling off use a wooden wedge to secure it. (8) Carefully remove masking tape from grid line. (10) After epoxy is properly cured remove wedge from terminal and check the operation of the rear window defogger. CAUTION: Do not allow the laminated windshield glass surface to exceed 82° C (180° F) or the glass may fracture. The rear window glass surface should not exceed 204° C (400° F). (9) Allow epoxy to cure 24 hours at room temperature. Fig. 5 Grid Line Repair 1 - BREAK 2 - GRID LINE 3 - MASKING TAPE HEATED MIRRORS RS 8G - 5 HEATED MIRRORS TABLE OF CONTENTS HEATED MIRRORS DESCRIPTION . . . . . . . . . OPERATION . . . . . . . . . . . DIAGNOSIS AND TESTING MIRROR TEST ....... MIRROR SWITCH DESCRIPTION . . . . . . . . . page page .................5 .................5 HEATED .................5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 HEATED MIRROR GRID STANDARD PROCEDURE - HEATED MIRROR . . 6 RELAY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 .................5 HEATED MIRRORS DESCRIPTION Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. OPERATION The heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the rear window defogger is ON (Fig. 1). DIAGNOSIS AND TESTING - HEATED MIRROR TEST Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the rear window defogger is ON. (1) The mirror glass should be warm to the touch. (2) If not, check the 20 amp fuse (11) in the Power Distribution Center (PDC) part of the Integrated Power Module (IPM) in the engine compartment. (3) Test voltage at rear window defogger switch. • If no voltage repair wire. • Remove mirror glass and test the wires for continuity. If no continuity repair wires. • If wires are OK, replace mirror glass. • To test defogger switch refer to the appropriate section in Electrical. MIRROR SWITCH DESCRIPTION The heated mirror switch is integrated into the rear window defogger switch located in the HVAC control panel (Fig. 1). Fig. 1 HVAC CONTROL PANEL 1 - TRIM BEZEL 2 - ACT SENSOR 3 - A/C REQUEST SWITCH 4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH COMBO 5 - FRONT WINDOW DEFROSTER MODE SELECTOR 8G - 6 HEATED MIRRORS RS MIRROR SWITCH (Continued) OPERATION A LED indicator will illuminate when the switch is activated. The switch energizes the HVAC control assembly when it requests the Front Control Module (FCM) to activate the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger and the heated power side view mirrors. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. HEATED MIRROR GRID STANDARD PROCEDURE - HEATED MIRROR Replacement of the mirror is necessary if the grid is damaged and diagnostics have been performed (Refer to 23 - BODY/EXTERIOR/SIDE VIEW MIRROR - REMOVAL). RELAY DESCRIPTION There is no heated mirror relay it is integrated into the (E.B.L) relay that is located in the IPM in the engine compartment. HEATED SEAT SYSTEM RS 8G - 7 HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DRIVER HEATED SEAT SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 HEATED SEAT ELEMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING - HEATED SEAT ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . HEATED SEAT SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - HEATED SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . PASSENGER HEATED SEAT SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . HEATED SEAT SYSTEM Vehicles with the heated seat option can be visually identified by the two separate heated seat switches located in the instrument panel center stack, just above the radio (Fig. 1). The heated seat system allows the front seat driver and passenger to select from two different levels of supplemental electrical seat heating (HI/LO), or no seat heating to suit their individual comfort requirements. The heated seat system for this vehicle includes the following major components, which are described in further detail later in this section: • Heated Seat Elements - Four heated seat elements are used per vehicle, two for each front seat. One heated seat element is integral to each front seat trim cover, one in the seat back and one in the seat bottom (cushion). Service replacement heating elements are available, refer to heated seat elements later in this section for additional information. • Heated Seat Modules - Two heated seat modules are used per vehicle. One module is mounted to each of the seat cushion pans, located under the forward edge of each front seat. Refer to heated seat module in the electronic control modules section of the service manual for additional information. • Heated Seat Sensors - Two heated seat sensors are used per vehicle, one for each front seat. The heated seat sensors are integral to each of the heated seat bottoms (cushions). DESCRIPTION Fig. 1 HEATED SEAT SWITCH LOCATIONS 1 - HEATED SEAT SWITCHES . . . . 12 . . . . 12 . . . . 12 . . . . 12 . . . . 12 . . . . 13 . . . . 13 . . . . 13 . . . . 14 . . . . 15 8G - 8 HEATED SEAT SYSTEM RS HEATED SEAT SYSTEM (Continued) • Heated Seat Switch - Two heated seat switches are used per vehicle, one for the driver and one for the passenger side front seats. The switches are mounted to in the instrument panel center stack. Refer to the description of the heated seat switch later in this section for additional information. Hard wired circuitry connects the heated seat system components to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the heated seat system components through the use of a combination of soldered splices and splice block connectors. Refer to Wiring for complete system wiring schematics. The wiring information also includes the 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. OPERATION The heated seat system components operate on battery current received through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the system will only operate when the ignition switch is in the On or Accessory positions. The heated seat system will be turned Off automatically whenever the ignition switch is turned to any position except On or Accessory. Also, the heated seat system will not operate when the surface temperature of the seat cushion cover at either heated seat sensor is above the designed temperature set points of the system. The heated seat system has a self-diagnostic capability. When certain failures are detected within the heated seat system, the system will provide a visual indication of the failure by flashing the Light Emitting Diode (LED) indicator lamps located in the heated seat switches. See the owner’s manual in the vehicle glove box for more information on the features, use and operation of the heated seat system. DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM Refer toWiring Diagrams for complete wiring schematics. The wiring information also includes the 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. HEATED SEAT SYSTEM DIAGNOSIS CONDITION NO HEATED SEAT SWITCH ILLUMINATION WITH IGNITION ON (SYSTEM ON) POSSIBLE CAUSES CORRECTION 1. Faulty fuse 1. Check heated seat fuse in Integrated Power Module. Replace fuse, repair short if required. 2. Faulty components 2. Refer to individual Heated Seat System components for the proper diagnosis and testing procedures. 3. Ground faulty 3. Check for ground at heated seat switch and module. Repair, if required. 4. Wiring faulty 4. Check fused ignition switch output (run-acc) circuits at switch and module. Repair, if required. HEATED SEAT SYSTEM RS DRIVER HEATED SEAT SWITCH DESCRIPTION 8G - 9 cator illuminates. When the switch rocker is moved to its neutral position (middle), Off is selected and both LED indicators are extinguished. Both switches provide separate resistor multiplexed hard wire inputs to the Heated Seat Module (HSM) to indicate the selected switch position. The heated seat module responds to the heated seat switch status messages by controlling the output to the seat heater elements of the selected seat. The Low heat position set point is about 36° C (97° F), and the High heat position set point is about 41° C (105° F). DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH For complete circuit diagrams, refer to Wiring Diagrams. WARNING: REFER TO THE RESTRAINTS SECTION OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig. 2 HEATED SEAT SWITCH LOCATION 1 - HEATED SEAT SWITCHES The heated seat switches are mounted in the instrument panel center bezel (Fig. 2). The two threeposition rocker-type switches, one switch for each front seat, are incorporated into one large switch assembly that also includes the hazard, rear window wiper and washer switches. The heated seat switches provide a resistor multiplexed signal to the Heated Seat Module (HSM) through separate hard wired circuits. Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has two Light-Emitting Diodes (LED) which light to indicate that the heater for the seat is turned on. The heated seat switches and their LEDs cannot be repaired. If either switch or LED is faulty or damaged, the entire switch assembly must be replaced. OPERATION There are three positions that can be selected with each of the heated seat switches: Off, Low, or High. When the left side of the switch rocker is fully depressed, the Low position is selected and the low position LED indicator illuminates. When the right side of the switch rocker is fully depressed, the High position is selected and the high position LED indi- CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE (1) Disconnect and isolate the battery negative cable. (2) Access and disconnect the gray 4-way connector from the heated seat module. Visually inspect wiring terminals for damage that would prevent positive connection. If not OK, repair or replace the necessary components. (3) Reconnect the negative battery cable and Turn heated seat ON in the LO position. Using an Ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 3.5 kiloohms (3500 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed. If NOT OK replace the switch or faulty wiring. (4) Turn heated seat ON in the HI position. Using an Ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 1.4 kiloohms (1400 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed. If NOT OK replace the switch or faulty wiring. (5) With the system ON in the HI position, Check for battery voltage and ground at cavities 4 and 1. If OK, proceed with testing remaining components. If NOT OK, repair open or wiring short. 8G - 10 HEATED SEAT SYSTEM RS DRIVER HEATED SEAT SWITCH (Continued) CHECKING SWITCH ONLY (1) Disconnect and isolate the battery negative cable. Remove the center bezel from the instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - REMOVAL). Check for continuity between the ground circuit cavity (#10) of the instrument panel switch bank electrical connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. (2) Reconnect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel switch bank connector (#4). If OK, turn the ignition switch to the Off position, and go to Step 3. If not OK, repair the open fused ignition switch output (run) circuit as required. (3) Test the heated seat switch as shown in the Heated Seat Switch Test chart and the connector pinout below (Fig. 3). If OK, go to Step 4. If not OK, replace the faulty switch bank assembly. If the system is still inoperative proceed with checking remaining components. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO THE RESTRAINTS SECTION OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument panel center bezel. Refer to Instrument Panel Center Bezel in the Body section for the procedure. (3) Remove the three screws (Fig. 4) that secure the heated seat switch to the back of the instrument panel center bezel. Fig. 3 Instrument Panel Switch Bank Connector DRIVER HEATED SEAT SWITCH TEST SWITCH POSITION RESISTANCE BETWEEN RESISTANCE (OHMS) Off Pin 4 & 5 OPEN Low Pin 4 & 5 3570 Pin 4 & 5 1430 High All resistance values are ±1%. (4) Reconnect the instrument panel switch bank and test the heated seat system for proper operation. Fig. 4 SWITCH RETAINING SCREWS 1 - HEATED SEAT SWITCH ASSEMBLY 2 - RETAINING SCREWS (4) Remove the heated seat switch from the back of the instrument panel center bezel. INSTALLATION (1) Position the heated seat switch onto the back of the instrument panel center bezel. RS HEATED SEAT SYSTEM 8G - 11 DRIVER HEATED SEAT SWITCH (Continued) (2) Install and tighten the three screws that secure the heated seat switch to the back of the instrument panel center bezel. Tighten the screws to 1.5 N·m (13 in. lbs.) (Fig. 4). (3) Install the center bezel onto the instrument panel. Refer to Instrument Panel Center Bezel in the Body section for the procedure. (4) Reconnect the battery negative cable. HEATED SEAT ELEMENT NOTE: WHEN CHECKING HEATED SEAT ELEMENTS FOR CONTINUITY, BE CERTAIN TO MOVE THE HEATING ELEMENT BEING CHECKED. MOVING THE ELEMENT, SUCH AS SITTING IN THE SEAT WILL ELIMINATE THE POSSIBILITY OF AN INTERMITTENT OPEN IN THE ELEMENT WHICH WOULD ONLY BE EVIDENT IF THE ELEMENT WAS MOVED IN A CERTAIN DIRECTION. FAILURE TO CHECK THE ELEMENT IN VARIOUS POSITIONS COULD RESULT IN AN INCOMPLETE TEST. DESCRIPTION SEAT CUSHION ELEMENT The heated seat system includes two seat heating elements in each front seat, one for the seat cushion and the other for the seat back. The two elements for each seat that are connected in series with the Heated Seat Module (HSM). The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat, and it is located on the seat cushion heating element for all models. The seat heating elements are sewn into the seat cushion cover trim and seat back cover trim units. The heated seat elements and the temperature sensor cannot be adjusted or repaired and, if faulty or damaged, the seat element assembly must be replaced. Refer to the procedure in this section. (1) From under the vehicle, remove the appropriate seats four retaining nuts. (2) From inside the vehicle, pull the seat up, off the mounting studs and lay it back, up against one of the rear seats. (3) Locate the heated seat module, attached to the bottom of the seat cushion pan. Remove the heated seat module from the seat cushion pan. Do not disconnect the electrical connectors at this time. (4) Locate the green 4-way electrical connector, connected to the heated seat module. Disconnect the green 4-way connector from the heated seat module. (5) Check for continuity between the two outboard circuit cavities of the wire harness connector (Pins 1&4). There should be continuity. If OK, refer to Heated Seat Module Diagnosis and Testing in the Electronic Control Modules section of the service manual for complete system testing procedures. If not OK, install a replacement heated seat cushion element. Refer to the procedure in this section. OPERATION The heated seat elements resist the flow of electrical current. When battery current is passed through the elements, the energy lost by the resistance of the elements to the current flow is released in the form of heat. The temperature sensor is a NTC thermistor. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies a five-volt current to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. DIAGNOSIS AND TESTING - HEATED SEAT ELEMENTS The wire harness connectors for the seat cushion and seat back heating elements are located under the seat, at the heated seat module. For circuit descriptions and diagrams, refer to section 8W, Wiring Diagrams. In order to access and test the heated seat elements it will be necessary to remove the appropriate front seat retaining bolts and lay the seat rearward, up against one of the rear seats. It is not necessary to disconnect the seat electrical connectors, just use care not to damage the attached wire harnesses while testing. SEAT BACK ELEMENT (1) From under the vehicle, remove the appropriate seats four retaining nuts. (2) From inside the vehicle, pull the seat up and off the mounting studs and lay it back, up against one of the rear seats. (3) Locate the heated seat module, attached to the bottom of the seat cushion pan. Remove the heated seat module from the seat cushion pan. Do not disconnect the electrical connectors at this time. (4) Locate the gray 2-way electrical connector, connected to the heated seat module. Disconnect the 2-way connector from the heated seat module. (5) Check for continuity between the two circuit cavities of the 2-way wire harness connector. There should be continuity. If OK, refer to Heated Seat Module Diagnosis and Testing in the Electronic Control Modules section of the service manual for complete system testing procedures. If not OK, install a replacement heated seat back element. Refer to the procedure in this section. 8G - 12 HEATED SEAT SYSTEM RS HEATED SEAT ELEMENT (Continued) REMOVAL Do not remove the OEM heating element from the seat or seat back cushion/trim covers. The original element is permanently attached and cannot be removed without permanent damage. The service replacement heating element is designed to be applied directly on the seat cushion. (1) Disconnect and isolate the negative battery cable. (2) Remove the appropriate seat cushion or seat back trim cover. Refer to the Body section of the service manual for the procedures. (3) Disconnect the inoperative heated seat cushion or seat back element electrical connectors. (4) Locate the wires leading from the inoperative heating element and cut them off flush with the edge of the original heating element. INSTALLATION (1) Peel off the adhesive backing on the back of the replacement heating element and stick directly on the foam cushion. CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. (2) Connect the new heating element electrical connectors (Fig. 5). (3) Connect the negative battery cable. (4) Verify heated seat system operation. (5) Install the appropriate seat cushion or seat back trim cover. Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. HEATED SEAT SENSOR DESCRIPTION Two heated seat sensors are used per vehicle, one in each front seat cushion heating element. The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The heated seat sensors cannot be repaired or adjusted and if found to be faulty, the complete heated seat cushion element must be replaced. Fig. 5 HEATING ELEMENT INSTALLED - TYPICAL 1 - SEAT BACK WIRE HARNESS 2 - HEATED SEAT WIRE HARNESS CONNECTOR 3 - HEATED SEAT CUSHION ELEMENT OPERATION The temperature sensor is a NTC thermistor. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies a five-volt current to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. DIAGNOSIS AND TESTING - HEATED SEAT SENSOR For complete circuit diagrams, refer to Wiring Diagrams. (1) Disconnect and isolate the battery negative cable. Disconnect the green 4-way heated seat module wire harness connector. (2) Using an ohmmeter, check the resistance between cavities 2 and 3. The sensor resistance should be between 2 kilohms at 15° C (60° F) and 50 kilohms at 30° C (85° F). If not OK, replace the faulty seat element and sensor assembly. HEATED SEAT SYSTEM RS PASSENGER HEATED SEAT SWITCH DESCRIPTION 8G - 13 cator illuminates. When the switch rocker is moved to its neutral position (middle), Off is selected and both LED indicators are extinguished. Both switches provide separate resistor multiplexed hard wire inputs to the Heated Seat Module (HSM) to indicate the selected switch position. The heated seat module responds to the heated seat switch status messages by controlling the output to the seat heater elements of the selected seat. The Low heat position set point is about 36° C (97° F), and the High heat position set point is about 41° C (105° F). DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH For complete circuit diagrams, refer to Wiring Diagrams. WARNING: REFER TO THE RESTRAINTS SECTION OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig. 6 HEATED SEAT SWITCH LOCATION 1 - HEATED SEAT SWITCHES The heated seat switches are mounted in the instrument panel center bezel (Fig. 6). The two threeposition rocker-type switches, one switch for each front seat, are incorporated into one large switch assembly that also includes the hazard, rear window wiper and washer switches. The heated seat switches provide a resistor multiplexed signal to the Heated Seat Module (HSM) through separate hard wired circuits. Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has two Light-Emitting Diodes (LED) which light to indicate that the heater for the seat is turned on. The heated seat switches and their LEDs cannot be repaired. If either switch or LED is faulty or damaged, the entire switch assembly must be replaced. OPERATION There are three positions that can be selected with each of the heated seat switches: Off, Low, or High. When the left side of the switch rocker is fully depressed, the Low position is selected and the low position LED indicator illuminates. When the right side of the switch rocker is fully depressed, the High position is selected and the high position LED indi- CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE (1) Disconnect and isolate the battery negative cable. (2) Access and disconnect the gray 4-way connector from the heated seat module. Visually inspect wiring terminals for damage that would prevent positive connection. If not OK, repair or replace the necessary components. (3) Reconnect the negative battery cable and Turn heated seat ON in the LO position. Using an Ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 3.5 kiloohms (3500 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed. If NOT OK replace the switch or faulty wiring. (4) Turn heated seat ON in the HI position. Using an Ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 1.4 kiloohms (1400 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed. If NOT OK replace the switch or faulty wiring. (5) With the system ON in the HI position, Check for battery voltage and ground at cavities 4 and 1. If OK, proceed with testing remaining components. If NOT OK, repair open or wiring short. 8G - 14 HEATED SEAT SYSTEM RS PASSENGER HEATED SEAT SWITCH (Continued) CHECKING SWITCH ONLY (1) Disconnect and isolate the battery negative cable. Remove the center bezel from the instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - REMOVAL). Check for continuity between the ground circuit cavity (#10) of the instrument panel switch bank electrical connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. (2) Reconnect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel switch bank connector (#4). If OK, turn the ignition switch to the Off position, and go to Step 3. If not OK, repair the open fused ignition switch output (run) circuit as required. (3) Test the heated seat switch as shown in the Heated Seat Switch Test chart and the connector pinout below (Fig. 7). If OK, go to Step 4. If not OK, replace the faulty switch bank assembly. (4) Reconnect the instrument panel switch bank and test the heated seat system for proper operation. If the system is still inoperative proceed with checking remaining components. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO THE RESTRAINTS SECTION OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument panel center bezel. Refer to Instrument Panel Center Bezel in the Body section for the procedure. (3) Remove the three screws (Fig. 8) that secure the heated seat switch to the back of the instrument panel center bezel. Fig. 7 Instrument Panel Switch Bank Connector PASSENGER HEATED SEAT SWITCH TEST SWITCH POSITION RESISTANCE BETWEEN RESISTANCE (OHMS) Off Pin 3 & 4 OPEN Low Pin 3 & 4 3570 Pin 3 & 4 1430 High All resistance values are ±1%. Fig. 8 SWITCH RETAINING SCREWS 1 - HEATED SEAT SWITCH ASSEMBLY 2 - RETAINING SCREWS (4) Remove the heated seat switch from the back of the instrument panel center bezel. HEATED SEAT SYSTEM RS 8G - 15 PASSENGER HEATED SEAT SWITCH (Continued) INSTALLATION (1) Position the heated seat switch onto the back of the instrument panel center bezel. (2) Install and tighten the three screws that secure the heated seat switch to the back of the instrument panel center bezel. Tighten the screws to 1.5 N·m (13 in. lbs.) (Fig. 8). (3) Install the center bezel onto the instrument panel. Refer to Instrument Panel Center Bezel in the Body section for the procedure. (4) Reconnect the battery negative cable. SUSPENSION RS 2-1 SUSPENSION TABLE OF CONTENTS page FRONT SUSPENSION .....................1 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 26 page WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 46 FRONT SUSPENSION TABLE OF CONTENTS page FRONT SUSPENSION DESCRIPTION - FRONT SUSPENSION . . . . . . . 2 OPERATION - FRONT SUSPENSION . . . . . . . . . 2 STANDARD PROCEDURE - LUBRICATION ....2 SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE . . 3 SPECIAL TOOLS FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 3 BUSHINGS REMOVAL - STABILIZER BAR CUSHION . . . . . . 4 INSTALLATION - STABILIZER BAR CUSHION . . . 4 HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIAGNOSIS AND TESTING - HUB AND BEARING ............................5 REMOVAL .............................5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 KNUCKLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL - STEERING KNUCKLE . . . . . . . . . . . 7 INSPECTION - STEERING KNUCKLE . . . . . . . . . 8 INSTALLATION - STEERING KNUCKLE . . . . . . . 9 LOWER BALL JOINT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DIAGNOSIS AND TESTING - LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOWER BALL JOINT SEAL BOOT DESCRIPTION - EXPORT . . . . . . . . . . . . . . . . . 10 REMOVAL REMOVAL - BALL JOINT SEAL BOOT . . . . . . 11 REMOVAL - EXPORT . . . . . . . . . . . . . . . . . . . 11 page INSTALLATION INSTALLATION - BALL JOINT SEAL BOOT INSTALLATION - EXPORT . . . . . . . . . . . . LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - LOWER CONTROL ARM . . . . . DISASSEMBLY DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD) . . . . . . . DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO) . . . . . . . . . . INSPECTION - LOWER CONTROL ARM . . . ASSEMBLY ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD) . . . . . . . ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO) . . . . . . . . . . INSTALLATION - LOWER CONTROL ARM . STABILIZER BAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . STRUT DESCRIPTION - STRUT ASSEMBLY . . . . . . OPERATION - STRUT ASSEMBLY ....... DIAGNOSIS AND TESTING - STRUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - STRUT ASSEMBLY . . . . . . . . . DISASSEMBLY - STRUT ASSEMBLY ..... ASSEMBLY - STRUT ASSEMBLY . . . . . . . . INSTALLATION - STRUT ASSEMBLY ..... . . 11 . . . 12 . . . 12 . . . 12 . . . 12 . . . 13 . . . 13 . . . 14 . . . 14 . . . 15 . . . 15 . . . . . . . . . . . 16 . 16 . 17 . 17 . 18 . . . 19 . . . 19 . . . . . . . . . . . 20 . 20 . 22 . 23 . 25 2-2 FRONT SUSPENSION RS strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint) turn as an assembly. FRONT SUSPENSION DESCRIPTION - FRONT SUSPENSION This vehicle has a MacPherson Strut type front suspension (Fig. 1). OPERATION - FRONT SUSPENSION The front suspension allows each wheel on a vehicle to adapt to different road surfaces and conditions without greatly affecting the opposite wheel and the ability to control the vehicle. Each side of the front suspension is allowed to pivot so the vehicle can be steered in the direction preferred. A strut assembly is used in place of the front suspension upper control arm and upper ball joint. When a vehicle strikes a bump, the force is transferred through the hub, bearing, and knuckle, into the strut assembly to absorb the force and dampen it. The top of the strut is mounted directly to the strut tower of the vehicle. During steering maneuvers, the STANDARD PROCEDURE - LUBRICATION There are no serviceable lubrication points on the front suspension. The ball joints are sealed-for-life and require no maintenance. The lower ball joints have special grease fitting caps that prevent normal grease gun attachment. This has been done to eliminate the possibility of over-filling, damaging the nonvented seal. Do not attempt to remove the special grease fitting cap and replace it with a normal grease zirc fitting. CAUTION: No attempt should be made to replace the ball joint grease fitting cap with a normal zirc fitting or fill the ball joint with grease. Damage to the grease seal can result. Fig. 1 Front Suspension 1 2 3 4 5 6 7 8 - TOWER CROSSMEMBER TAPPING PLATES LEFT STRUT ASSEMBLY LEFT STEERING KNUCKLE (WITH HUB AND BEARING) STABILIZER BAR LINK STABILIZER BAR LEFT LOWER CONTROL ARM CRADLE/CROSSMEMBER 9 - CRADLE/CROSSMEMBER REINFORCEMENT 10 - BALL JOINT 11 - ISOLATOR BUSHING 12 - STEERING GEAR TIE ROD 13 - RIGHT STEERING KNUCKLE 14 - RIGHT HUB AND BEARING 15 - RIGHT STRUT ASSEMBLY FRONT SUSPENSION RS SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE N·m Ft. Lbs. In. Lbs. Ball Joint Nut 108 80 — Cradle Crossmember Mounting Bolts 163 120 — Cradle Crossmember Reinforcement Bolts - Size M-14 153 113 — Cradle Crossmember Reinforcement Bolt - Size M-12 106 78 — Cradle Crossmember Reinforcement Bolts - Size M-10 61 45 — Disc Brake Adapter Mounting Bolts 169 125 — Hub And Bearing Mounting Bolts 65 45 — Hub And Bearing Axle Hub Nut 244 180 — Lower Control Arm Pivot Bolt 183 135 — Stabilizer Bar Bushing Retainer Bolts 68 50 — Stabilizer Bar Link Nuts 88 65 — Strut Body/Tower Mounting Nuts 28 21 250 81 + 90° turn 60 + 90° turn — Strut Shaft Nut 100 75 — Tie Rod Adjuster Jam Nut 75 55 — Tie Rod Steering Arm Nut 75 55 — Wheel Mounting (Lug) Nuts 135 100 — DESCRIPTION Strut Clevis-to-Knuckle Nuts Press, Ball Joint C-4212F Installer, Ball Joint 6758 Wrench, Strut Rod Nut 6864 SPECIAL TOOLS FRONT SUSPENSION REMOVER/INSTALLER, BUSHING 8460 Puller C-3894A REMOVER/INSTALLER, BALL JOINT 8490 2-3 2-4 FRONT SUSPENSION RS BUSHINGS REMOVAL - STABILIZER BAR CUSHION (1) Raise Vehicle. Refer to Hoisting in Lubrication and Maintenance. (2) Remove the 2 bolts fastening the emission leak detection pump to the cradle crossmember reinforcement. (3) Move the leak detection pump to the side allowing access to the stabilizer bar cushion retainers. (4) Remove the nut and bolt securing each stabilizer bar cushion retainer to the cradle crossmember (Fig. 2) and remove the retainers. Fig. 3 Correctly Installed Stabilizer Bar Cushion 1 2 3 4 - SLIT IN SWAY BAR BUSHING. SQUARE CORNER SWAY BAR SWAY BAR ISOLATOR BUSHING (4) Install each mounting bolt from rear of cradle crossmember through retainer. Install the two nuts and tighten to 68 N·m (50 ft. lbs.) torque. (5) Reattach emission leak detection pump to cradle crossmember reinforcement with two mounting bolts. (6) Lower the vehicle. Fig. 2 Front Stabilizer Bar Cushion Retainers 1 2 3 4 5 - STEERING GEAR STABILIZER BAR RAISED BEAD FRONT CRADLE CROSSMEMBER RETAINERS (5) Remove each stabilizer bar cushion from the stabilizer bar by opening the slit in the cushion and peeling it off the stabilizer bar. INSTALLATION - STABILIZER BAR CUSHION (1) Install each new cushion on stabilizer bar by spreading cushion at slit and forcing it onto stabilizer bar. NOTE: Cushions must be installed on stabilizer bar so the square corner of the bushing will be down and slit in cushion will be facing the rear of the vehicle when the stabilizer bar is installed (Fig. 3). (2) Place stabilizer bar into mounted position with cushions properly aligned. (3) Hook each retainer into cradle crossmember mounting hole and over cushion. HUB / BEARING DESCRIPTION The front wheel bearing and front wheel hub of this vehicle are a hub and bearing unit type assembly (Unit III). This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a sealed one-piece unit. The hub and bearing is mounted to the center of the steering knuckle (Fig. 1). It is retained by four mounting bolts accessible from the inboard side of the steering knuckle. The hub flange has five wheel mounting studs. The wheel mounting studs used to mount the tire and wheel to the vehicle are the only replaceable components of the hub and bearing assembly. Otherwise, the hub and bearing is serviced only as a complete assembly. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft, along with the tire and wheel. The five wheel mounting studs mount the tire and wheel, and brake rotor to the vehicle. FRONT SUSPENSION RS 2-5 HUB / BEARING (Continued) DIAGNOSIS AND TESTING - HUB AND BEARING The condition of the front hub and bearing assembly is diagnosed using the inspection and testing procedure detailed below. The bearing contained in the Unit III front hub/ bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Fig. 4 Hub Nut 1 2 3 4 - HUB NUT NUT LOCK COTTER PIN SPRING WASHER 1 2 3 4 5 6 7 - BRAKE ROTOR - HUB AND BEARING - STEERING KNUCKLE - ADAPTER MOUNTING BOLTS - BRAKE CALIPER - ADAPTER - CLIP REMOVAL NOTE: Replacement of the Unit III front hub/bearing assembly can be normally done without having to remove the steering knuckle from the vehicle. In the event that the hub/bearing is frozen in the steering knuckle and cannot be removed by hand, it will have to be pressed out of the steering knuckle. The steering knuckle will require removal from the vehicle to allow the hub/bearing assembly to be pressed out of the steering knuckle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE - REMOVAL) (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove wheel lug nuts, and front tire and wheel assembly. (3) Remove the cotter pin, nut lock and spring washer from the stub axle (Fig. 4). (4) With aid of a helper applying the brakes to keep the front hub from turning, remove the hub nut (Fig. 4). (5) Remove disc brake caliper and adapter as an assembly from knuckle as shown (Fig. 5). Hang assembly out of the way using a bungee cord or wire. Do not allow caliper hang by brake hose. (6) Remove brake rotor from hub and bearing (Fig. 5). (7) Push in on end of driveshaft stub shaft, pushing its splines out of the hub splines. Fig. 5 Front Brake Mounting (8) Remove the four hub and bearing mounting bolts from the rear of steering knuckle (Fig. 6). Use care not to come in contact with and damage the ABS tone wheel on the driveshaft stub shaft upon bolt removal. (9) Remove the hub and bearing assembly from the steering knuckle. 2-6 FRONT SUSPENSION RS HUB / BEARING (Continued) Fig. 6 Hub And Bearing Mounting Bolts 1 2 3 4 - HUB STEERING KNUCKLE MOUNTING BOLTS (4) DRIVESHAFT INSTALLATION CAUTION: Hub and bearing assembly mounting surfaces on the steering knuckle and stub axle (Fig. 7) must be smooth and completely free of foreign material or nicks prior to installing hub and bearing assembly. (1) Install hub and bearing onto stub axle and into steering knuckle until squarely seated on the face of the steering knuckle. (2) Install the 4 hub and bearing mounting bolts from the rear of the knuckle. Equally tighten all 4 mounting bolts in a criss-cross pattern until hub/ bearing assembly is squarely seated against front of steering knuckle. Tighten mounting bolts to a torque of 65 N·m (45 ft. lbs.) (3) Install the brake rotor on the hub and bearing (Fig. 5). (4) Install brake caliper and adapter assembly back over brake rotor and align with mounting holes on steering knuckle (Fig. 5). Install the mounting bolts and tighten to 169 N·m (125 ft. lbs.) torque. (5) Install the hub nut on the end of the stub axle (Fig. 4). With aid of a helper applying the brakes to keep the front hub from turning, tighten the hub nut to Install the mounting bolts and tighten to 244 N·m (180 ft. lbs.) torque. (6) Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (7) Lower vehicle to the ground. (8) Check the front wheel alignment toe setting and reset if not within specifications. (Refer to 2 SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE) KNUCKLE DESCRIPTION Fig. 7 Mounting Surfaces (Typical) 1 - BEARING SEAL 2 - STUB AXLE 3 - THESE SURFACES MUST BE CLEAN AND FREE OF NICKS BEFORE INSTALLING BEARING ASSEMBLY 4 - STEERING KNUCKLE CAUTION: When installing hub and bearing into steering knuckle, be careful not to damage the bearing seal (Fig. 7) on the outer C/V joint. The steering knuckle is a single aluminum casting with legs machined for attachment of the strut assembly, steering linkage, disc brake caliper adapter, lower control arm ball joint and steering linkage (Fig. 1). The hub and bearing assembly is mounted in the center of the steering knuckle using 4 bolts. The driveshaft’s constant velocity (C/V) stub axle is splined through the center of the hub and bearing and is held in place using a nut, nut lock and cotter pin. Service replacement of the front hub and bearing assembly can be done with the steering knuckle remaining on the vehicle. OPERATION The steering knuckle pivots with the strut assembly between the lower ball joint and the pivot bearing in the strut assembly. The steering gear outer tie rod end connects to the trailing end of each knuckle, allowing the vehicle to be steered. FRONT SUSPENSION RS KNUCKLE (Continued) The center of the knuckle supports the hub and bearing and axle shaft. REMOVAL - STEERING KNUCKLE (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove the wheel and tire assembly from the vehicle. (3) Remove the cotter pin, nut lock and spring washer from the end of the stub axle and hub nut (Fig. 8). Fig. 9 Front Brake Mounting 1 2 3 4 5 6 7 - BRAKE ROTOR - HUB AND BEARING - STEERING KNUCKLE - ADAPTER MOUNTING BOLTS - BRAKE CALIPER - ADAPTER - CLIP Fig. 8 Hub Nut 1 2 3 4 - HUB NUT NUT LOCK COTTER PIN SPRING WASHER (4) Have a helper apply the vehicle’s brakes to keep hub from turning, loosen and remove the hub nut (Fig. 8). (5) Remove disc brake caliper and adapter as an assembly from knuckle as shown (Fig. 9). Hang assembly out of the way using a bungee cord or wire (Fig. 10). Do not allow caliper to hang by brake hose. (6) Remove nut attaching outer tie rod end to steering knuckle by holding the tie rod end stud while loosening and removing nut with a wrench (Fig. 11). (7) Remove tie rod end from steering knuckle using Remover, Special Tool C-3894–A (Fig. 12). (8) If equipped with antilock brakes, remove the front wheel speed sensor from the steering knuckle (Fig. 13). (9) Remove the two steering knuckle-to-strut clevis bracket attaching bolts. (10) Tip the knuckle outward and remove the driveshaft stub axle from the hub and bearing. Suspend driveshaft straight outward using a bungee cord or wire (Fig. 10). Do not allow driveshaft to hang by inner joint. Fig. 10 Caliper And Driveshaft Suspended 1 2 3 4 - HANGER SUSPENDING CALIPER HANGER SUSPENDING DRIVESHAFT DRIVESHAFT BRAKE CALIPER 2-7 2-8 FRONT SUSPENSION RS KNUCKLE (Continued) Fig. 11 Removing Tie Rod End Attaching Nut 1 2 3 4 5 - TIE ROD END STEERING KNUCKLE WRENCH SOCKET TIE ROD END STUD Fig. 13 Front Wheel Speed Sensor 1 - MOUNTING BOLT 2 - WHEEL SPEED SENSOR 3 - STEERING KNUCKLE in the knuckle at this time, it is not necessary to hold the stud stationary to remove the nut. (12) Reinstall the ball joint nut until the top of the nut is even with the top of the ball joint stud. This will keep the stud from distorting while the stud is released from the knuckle in the following step. CAUTION: Do not remove ball joint stud from steering knuckle using a hammer. Damage to the Aluminum knuckle, ball joint or control arm will result. (13) Release ball joint stud from steering knuckle using Remover, Special Tool C-4150A, as shown (Fig. 14). To ease Remover installation and use, it may help to rotate the knuckle around so the inside of the knuckle faces outward. (14) Remove the nut from the top of the ball joint stud. (15) Remove the steering knuckle from the vehicle. (16) If the hub and bearing needs to be transferred, remove the four bolts attaching the hub and bearing to the knuckle, then remove the hub and bearing. INSPECTION - STEERING KNUCKLE Fig. 12 Tie Rod Removal With Tool C-3894-A 1 - OUTER TIE ROD 2 - SPECIAL TOOL C-3894-A 3 - STEERING KNUCKLE (11) Remove ball joint nut using a power impact wrench. Because the tapered stud is held sufficiently Inspect the knuckle for the following: • Cracks or breaks • Dents or damage • Stress marks indicating a bend The front suspension knuckle is not a repairable component of the vehicles front suspension. If bent, broken or damaged in any way, do not attempt to straighten or repair the steering knuckle. It must be replaced. FRONT SUSPENSION RS 2-9 KNUCKLE (Continued) wrench, tighten the nut to a torque of 108 N·m (80 ft. lbs.). Fig. 15 Ball Joint Nut Installation 1 - KNUCKLE 2 - BALL JOINT STUD 3 - LOWER CONTROL ARM Fig. 14 Using C-4150A To Release Ball Joint 1 2 3 4 - ALUMINUM KNUCKLE - SPECIAL TOOL C-4150A - LOWER CONTROL ARM - NUT INSTALLED ON BALL JOINT STEM If inspection leads to the hub and bearing, (Refer to 2 - SUSPENSION/FRONT/HUB / BEARING DIAGNOSIS AND TESTING) INSTALLATION - STEERING KNUCKLE (1) If the hub and bearing needs to be installed in the knuckle, place the hub and bearing squarely into the center hole of the steering knuckle aligning the threaded mounting holes of the hub and bearing with the mounting holes in the steering knuckle. Install the four mounting bolts and tighten them to a torque of 65 N·m (45 ft. lbs.). CAUTION: Before installing the knuckle on the ball joint stud, wipe the ball joint stud and knuckle contact area free of any grease or debris, otherwise damage to the knuckle can occur. Use a clean shop cloth with MoparT Brake Parts Cleaner applied to it for proper cleaning. Do not spray the stud directly. (2) Place the knuckle on the ball joint stud. (3) Install a NEW steering knuckle to ball joint stud nut. Tighten the nut by holding ball joint stud with hex wrench while turning nut with a wrench (Fig. 15). Using a crowsfoot wrench on a torque (4) Slide driveshaft stub axle into hub and bearing assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckle. CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket (Fig. 16). NOTE: The strut clevis-to-steering knuckle bolts are installed differently on each side. Left hand side bolts are to be installed from vehicle rear to front. Right side bolts are to be installed from vehicle front to rear. (5) Install steering knuckle in clevis bracket of strut damper assembly. Install the strut clevis-tosteering knuckle attaching bolts. Tighten both bolts to a torque of 81 N·m (60 ft. lbs.) plus an additional 1/4 (90°) turn. (6) Install tie rod end into knuckle steering arm. Start nut onto stud of tie rod end. While holding stud of tie rod end stationary using a socket (Fig. 11), tighten tie rod end to steering knuckle attaching nut. Tighten the tie rod end nut to a torque of 75 N·m (55 ft. lbs.). 2 - 10 FRONT SUSPENSION RS KNUCKLE (Continued) LOWER BALL JOINT DESCRIPTION Fig. 16 Correctly Installed Eccentric Attaching Bolt 1 2 3 4 - STEERING KNUCKLE FLANGED BOLT IN TOP HOLE CAM BOLT IN BOTTOM HOLE STRUT CLEVIS BRACKET (7) If equipped with antilock brakes, install wheel speed sensor and mounting bolt on steering knuckle (Fig. 13). Tighten the speed sensor bolt to a torque of 7 N·m (60 in. lbs.). (8) Install brake rotor on hub and bearing (Fig. 9). (9) Install disc brake caliper and adapter assembly on steering knuckle. Install adapter amounting bolts and tighten to 169 N·m (125 ft. lbs.). (10) Clean any debris from the threads of the outer C/V joint stub axle. (11) Install the washer and hub nut on stub axle. (12) Have a helper apply the vehicle’s brakes to keep hub from turning, then tighten hub nut to a torque of 244 N·m (180 ft. lbs.). (13) Install the spring wave washer on the end of the stub axle. (14) Install the hub nut lock, and a new cotter pin (Fig. 8). Wrap cotter pin prongs tightly around the hub nut lock. (15) Install wheel and tire assembly. Install and tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (16) Lower vehicle. (17) Set front wheel alignment camber and toe as necessary. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE) The ball joint is an integral part of the lower control arm (Fig. 1). The ball joint has a tapered stud that is pressed into the aluminum knuckle. The ball joint stud is threaded on the end for a retainer nut. The ball joint has a non-vented seal boot. The seal boot has an integrated heat shield. The ball joint used in the lower control arm of this vehicle is a sealed-for-life ball joint and requires no maintenance lubrication. The ball joint has been lubricated-for-life during the manufacturing process. A special fitting cap is installed on the fill port. This cap must not be removed and replaced with a common zirc fitting. The special cap is there to eliminate the possibility of lubrication latter during the ball joints life, thus damaging the non-vented seal boot. NOTE: The ball joint does not require any type of additional lubrication for the life of the vehicle. No attempt should be made to ever add any lubrication to the lower ball joint. OPERATION The ball joint is a pivotal joint on the lower control arm that allows the knuckle to move up and down, and turn with ease. DIAGNOSIS AND TESTING - LOWER BALL JOINT With the weight of the vehicle resting on the road wheels, grasp the special fitting cap on the bottom of the ball joint and with no mechanical assistance or added force, attempt to rotate the grease fitting. If the ball joint is worn, the grease fitting will rotate easily. If movement is noted, replacement of the control arm is recommended. LOWER BALL JOINT SEAL BOOT DESCRIPTION - EXPORT The lower ball joint seal boot is a two piece unit. It consists of the seal boot, plus a separate shield that is located in a groove at the top of the seal boot. NOTE: The seal boot should only be replaced if damaged during vehicle service. The entire lower control arm should be replaced if the joint has been contaminated. FRONT SUSPENSION RS 2 - 11 LOWER BALL JOINT SEAL BOOT (Continued) REMOVAL REMOVAL - BALL JOINT SEAL BOOT (1) Remove steering knuckle from vehicle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE REMOVAL) (2) Using a screw driver or other suitable tool, pry the seal boot off of the ball joint (Fig. 17) Fig. 18 Ball Joint Seal Boot Installed Position (Typical) 1 2 3 4 Fig. 17 Ball Joint Seal Boot Removal (Typical) 1 2 3 4 5 - LOWER CONTROL ARM BALL JOINT STUD SEAL BOOT SCREW DRIVER BALL JOINT ASSEMBLY (3) Inspect the ball joint for evidence of dirt or water intrusion and wipe clean as necessary. If dirt or water intrusion is extreme and joint cannot be properly cleaned, the lower control arm will need to be replaced. (Refer to 2 - SUSPENSION/FRONT/ LOWER CONTROL ARM - REMOVAL) - BALL JOINT SEAL BOOT BALL JOINT STUD LOWER CONTROL ARM SHIELD CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. (3) Place Installer, Special Tool 6758, over seal boot and squarely align it with bottom edge of seal boot (Fig. 19). Apply hand pressure (or gently tap with a hammer) to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm. REMOVAL - EXPORT (1) Remove steering knuckle from vehicle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE REMOVAL) (2) Remove shield from seal boot by gently pulling on it. (3) Using a screw driver or other suitable tool, pry seal boot off lower ball joint. INSTALLATION INSTALLATION - BALL JOINT SEAL BOOT (1) Place a liberal dab of Mopart Wheel Bearing Grease around the base of the ball joint stem at the socket. (2) Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to be with the shield positioned as shown (Fig. 18). Fig. 19 Installing Ball Joint Seal Boot 1 2 3 4 - SHIELD SPECIAL TOOL 6758 LOWER CONTROL ARM BALL JOINT SEAL BOOT 2 - 12 FRONT SUSPENSION RS LOWER BALL JOINT SEAL BOOT (Continued) (4) Wipe any grease off the ball joint stem using a clean shop towel with Mopart Brake Parts Cleaner applied to it. CAUTION: Do not attempt to install a normal grease zirc in the ball joint and lubricate the joint through the zirc fitting. CAUTION: Do not attempt to install a normal grease zirc in the ball joint an lubricate the joint through the zirc fitting. (6) Reinstall steering knuckle on vehicle. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION) (5) Reinstall steering knuckle on vehicle. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION) LOWER CONTROL ARM INSTALLATION - EXPORT (1) Place a liberal dab of Mopart Wheel Bearing Grease around the base of the ball joint stem at the socket. (2) Install a NEW seal boot by hand as far as possible on the ball joint. CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. (3) Place Installer, Special Tool 6758, over seal boot and squarely align it with bottom edge of seal boot (Fig. 20). Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm. DESCRIPTION The lower control arm is mounted to the front suspension crossmember using a pivot bolt through the center of the front pivot bushing, and the front suspension cradle crossmember reinforcement traps the rear bushing in the crossmember (Fig. 1). The lower control arm is an iron casting with two rubber bushings and a ball joint. The lower control arm front bushing is the spool type and is pressed into the lower control arm. The standard (Low-line) lower control arm rear bushing is a push-on bushing that is pushed over a stem on the rear of the lower control arm. The optional (High-line, Premium, Sport) lower control arm rear bushing is a hydrobushing that is pressed on. It has liquid filled voids that provide more effective dampening than the standard bushing. Vehicles with rear hydro-bushings utilize a different lower control arm than vehicles with standard bushings. They have a straight slightly tapered round stem where the hydro-bushing is mounted whereas the standard arm has a straight stem with a squared knob on the end to retain the bushing. The lower control arm ball joint is pressed into the outer end of the arm. The ball joint has a tapered stud and retainer nut for fastening it to the steering knuckle. OPERATION The lower control arm supports the lower end of the steering knuckle and allows for the up and down movement of the suspension during the jounce and rebound travel. The lower control arm ball joint connects the arm to the steering knuckle. Fig. 20 Installing Ball Joint Seal Boot (Typical) 1 2 3 4 - SHIELD (NOT ON RG VEHICLE) SPECIAL TOOL 6758 LOWER CONTROL ARM BALL JOINT SEAL BOOT (4) Wipe any grease off the ball joint stem. (5) Place the shield over the top of the seal boot and stretch it into the groove at the top of the seal boot. REMOVAL - LOWER CONTROL ARM (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove wheel and tire assembly. (3) Remove the steering knuckle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE - REMOVAL) (4) Remove the bolts fastening the power steering cooler to the front suspension cradle crossmember reinforcement (Fig. 21). FRONT SUSPENSION RS 2 - 13 LOWER CONTROL ARM (Continued) Fig. 21 Power Steering Cooler 1 - CRADLE CROSSMEMBER REINFORCEMENT 2 - POWER STEERING COOLER (5) Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of three different thread sizes. Note the location of the various sizes. (6) Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle crossmember (Fig. 22). Remove the 2 bolts fastening the reinforcement and rear of cradle crossmember to the body of the vehicle. Remove the reinforcement. (7) Remove the pivot bolt attaching the front bushing of the lower control arm to the front suspension cradle crossmember. (8) Remove the lower control arm. DISASSEMBLY DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD) (1) Remove the lower control arm from the front suspension cradle. (Refer to 2 - SUSPENSION/ FRONT/LOWER CONTROL ARM - REMOVAL) (2) Mount the lower control arm in a vise without using excessive clamping force. (3) Using a sharp knife (such as a razor), slit the bushing lengthwise (Fig. 23) to allow its removal from the lower control arm (Fig. 23). (4) Remove the bushing from the lower control arm. Fig. 22 Cradle Crossmember Reinforcement Attachment 1 2 3 4 5 6 7 - STEERING GEAR RIGHT LOWER CONTROL ARM LEFT LOWER CONTROL ARM CRADLE CROSSMEMBER REINFORCEMENT REAR CRADLE CROSSMEMBER ISOLATOR BUSHING STABILIZER BAR CRADLE CROSSMEMBER DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO) (1) Remove the lower control arm from the front suspension cradle. (Refer to 2 - SUSPENSION/ FRONT/LOWER CONTROL ARM - REMOVAL) (2) Mount the lower control arm in a vise without using excessive clamping force. (3) Install Remover, Special Tool 8460, on hydrobushing as shown (Fig. 24). Removal Pin, Special Tool 8460–3, must extend though hole in center of bushing rear. (4) Tighten forcing screw of Bridge (Special Tool 8460–1), removing bushing from lower control arm. 2 - 14 FRONT SUSPENSION RS LOWER CONTROL ARM (Continued) Inspect and test the ball joint per the procedure listed in Lower Ball Joint. (Refer to 2 - SUSPENSION/FRONT/LOWER BALL JOINT - DIAGNOSIS AND TESTING) ASSEMBLY ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD) CAUTION: Do not apply grease or any other type of lubricant other than the silicone lubricant specified below to the control arm bushing. Fig. 23 Slit Lower Control Arm Rear Bushing 1 - REAR BUSHING 2 - SLIT CUT IN BUSHING 3 - LOWER CONTROL ARM (1) Apply Mopar Silicone Spray Lube or an equivalent, to the hole in lower control arm rear bushing. This will aid in the installation of the bushing on the lower control arm. (2) With the lower control arm held securely in a vise, install bushing on lower control arm. Install bushing by pushing and rocking the bushing until it is fully installed on lower control arm. Be sure that when bushing is installed it is past the upset on the end of the lower control arm (Fig. 25). (3) The rear bushing of the lower control arm, when correctly installed, is to be positioned on the lower control arm as shown (Fig. 25). Fig. 24 HYDRO-BUSHING REMOVAL 1 2 3 4 - REMOVAL PIN (8460-3) BRIDGE (8460-1) HYDRO-BUSHING LOWER CONTROL ARM INSPECTION - LOWER CONTROL ARM Inspect lower control arm for signs of damage from contact with the ground or road debris. If lower control arm shows any sign of damage, inspect lower control arm for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. If damaged, the lower control arm casting is serviced only as a complete component. Inspect both lower control arm isolator bushings for severe deterioration, and replace as required. Inspect the rear hydro-bushing for seepage. Both type rear bushings are serviceable. If the front bushing fails, the lower control arm must be replaced. Fig. 25 Correctly Installed Lower Control Arm Bushing 1 2 3 4 5 - ROUND SURFACE OF BUSHING LOWER CONTROL ARM LOWER CONTROL ARM REAR BUSHING UPSET FLAT SURFACE OF BUSHING (4) Install lower control arm on vehicle. (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM INSTALLATION) FRONT SUSPENSION RS 2 - 15 LOWER CONTROL ARM (Continued) ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO) CAUTION: Do not apply grease or any other type of lubricant to the arm stem where the bushing is to be mounted. Such action will reduce proper bushing adhesion to arm. (1) Secure lower control arm in a vise. NOTE: Hydro bushings and grooves on control arm stems are unique for right and left sides. Left side bushing master spline and control arm groove are on the top (when mounted on vehicle). Right side bushing master spline and control arm groove are on the bottom (when mounted on vehicle). (2) Align master spline on bushing inner sleeve with groove on lower control arm rear bushing stem (Fig. 26). Start bushing on stem by hand. Fig. 27 HYDRO-BUSHING INSTALLATION 1 2 3 4 - LOWER CONTROL ARM FLANGE INSTALLER CUP (8460-2) BRIDGE (8460-1) HYDRO-BUSHING Fig. 26 BUSHING MASTER SPLINE LINED UP WITH GROOVE (RIGHT SIDE SHOWN) 1 - GROOVE 2 - HYDRO-BUSHING 3 - MASTER SPLINE (3) Install Remover/Installer, Special Tool 8460, over bushing and lower control arm as shown (Fig. 27). Engage flange on lower control arm with tips of Bridge, Special Tool 8460–1 as shown (Fig. 27). The contoured side of Installer Cup, Special Tool 8460–2, should be fitted up against rear of the bushing. (4) Begin to tighten forcing screw. As bushing nears lower control arm flange, place Spacer Plate, Special Tool 8460–4 between flange and bushing inner sleeve, straddling the stem as shown (Fig. 28). (5) Install bushing up against Spacer Plate, tightening the bridge forcing screw with a torque wrench until approximately 50 N·m (37 ft. lbs.) torque is Fig. 28 SPACER PLATE POSITIONED 1 2 3 4 5 - SPACER PLATE (8460-4) LOWER CONTROL ARM FLANGE BRIDGE (8460-1) INSTALLER CUP (8460-2) HYDRO-BUSHING reached. This will properly space bushing on the stem in relation to the flange. (6) Back off the forcing screw and remove tool. (7) Install lower control arm on vehicle. (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM INSTALLATION) INSTALLATION - LOWER CONTROL ARM (1) Position lower control arm assembly into front suspension cradle crossmember guiding bushings into mounting position (Fig. 22). 2 - 16 FRONT SUSPENSION RS LOWER CONTROL ARM (Continued) (2) Install NEW pivot bolt attaching front bushing of lower control arm to front suspension cradle crossmember (Fig. 29). Do not tighten or torque pivot bolt at this time. Fig. 30 Jack Stands Supporting Vehicle Weight Fig. 29 Lower Control Arm Bushing Pivot Bolt Correctly Installed 1 - PIVOT BOLT 2 - LOWER CONTROL ARM 3 - FRONT SUSPENSION CRADLE CROSSMEMBER (3) Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember (Fig. 22). Tighten the M-14 size bolts to a torque of 153 N·m (113 ft. lbs.). Tighten the M-12 size bolts to a torque of 106 N·m (78 ft. lbs.). (4) Install the lower control arm rear bushing retainer bolts through reinforcement on each side of each lower control arm rear bushing. Tighten these M-10 size bolts to a torque of 61 N·m (45 ft. lbs.). (5) Install the two bolts and bushings attaching the reinforcement and rear of cradle crossmember to body of vehicle (Fig. 22). Tighten bolts to a torque of 163 N·m (120 ft. lbs.). (6) Install the power steering cooler (Fig. 21). Tighten bolts to a torque of 11 N·m (100 in. lbs.). (7) Reinstall steering knuckle, brake rotor and caliper. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION) CAUTION: When locating jack stands under lower control arms, do not place the jack stands under the ball joints (Fig. 30). (8) Position jack stands under the lower control arms as close to the ball joints as possible (Fig. 30). Lower the vehicle onto the jack stands until the jack stands are supporting the total weight of the vehicle. (9) Tighten front lower control arm pivot bolt to a torque of 183 N·m (135 ft. lbs.). 1 2 3 4 - LOWER CONTROL ARMS BALL JOINT JACK STANDS BALL JOINT (10) Install the wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (11) Raise vehicle, remove jack stands and lower vehicle to the ground. (12) Perform front wheel alignment as necessary. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT STANDARD PROCEDURE) STABILIZER BAR DESCRIPTION The stabilizer bar interconnects both front struts of the vehicle and is attached to the front crossmember (Fig. 1) . Attachment of the stabilizer bar to the front crossmember is through 2 rubber-isolator cushion bushings and retainers. A double ball jointed stabilizer bar link is used to attach each end of the stabilizer bar to the front strut assemblies. All parts of the stabilizer bar are replaceable as individual components. The stabilizer bar to front crossmember cushion bushings are split for easy removal and installation. The split in the bushings should be positioned toward the rear of the vehicle, with the square corner facing down, when the stabilizer bar is installed. OPERATION Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel of the vehicle through the stabilizer bar. This helps FRONT SUSPENSION RS 2 - 17 STABILIZER BAR (Continued) to minimize the body roll of the vehicle during suspension movement. Connecting the stabilizer bar links to the strut assemblies helps reduce the fore-and-aft rate of the stabilizer bar from the rest of the front suspension. REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove the bolts fastening the power steering cooler to the front suspension cradle crossmember reinforcement (Fig. 31). Fig. 32 Cradle Crossmember Reinforcement Attachment Fig. 31 Power Steering Cooler 1 - CRADLE CROSSMEMBER REINFORCEMENT 2 - POWER STEERING COOLER (3) Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of two different thread sizes. Note the location of the various sizes. (4) Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle crossmember (Fig. 32). Remove the 2 bolts fastening the reinforcement and rear of cradle crossmember to the body of the vehicle. Remove the reinforcement. CAUTION: When removing the nut from the stud of the stabilizer bar link, do not allow the stud to rotate in it’s socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud (Fig. 33). 1 2 3 4 5 6 7 - STEERING GEAR RIGHT LOWER CONTROL ARM LEFT LOWER CONTROL ARM CRADLE CROSSMEMBER REINFORCEMENT REAR CRADLE CROSSMEMBER ISOLATOR BUSHING STABILIZER BAR CRADLE CROSSMEMBER (5) Remove the stabilizer bar links from each end of the stabilizer bar (Fig. 33). To do so, place an openend wrench on the flat machined into the link’s mounting stud, then remove the nut while holding the wrench in place. Push each stud out of the hole in the stabilizer bar. (6) Remove the stabilizer bar bushing (cushion) retainers from the front suspension cradle crossmember (Fig. 34). (7) Remove the stabilizer bar and bushings (cushions) as an assembly from the front suspension cradle crossmember. INSPECTION Inspect for broken or distorted stabilizer bar bushings (cushions), bushing retainers, and worn or damaged stabilizer bar links. 2 - 18 FRONT SUSPENSION RS STABILIZER BAR (Continued) (1) If the stabilizer bar to front suspension cradle bushings require replacement at time of inspection, install new bushings before installing stabilizer bar. Bushings are replaced by opening slit on bushings and peeling them off stabilizer bar. Install new bushings on stabilizer bar by spreading bushing at slit and forcing them on the stabilizer bar. Bushings must be installed on stabilizer bar so slit in bushing will be facing toward the rear of vehicle with the square corner toward the ground, when the stabilizer bar is installed on the vehicle (Fig. 35). Fig. 33 Stabilizer Bar Link To Stabilizer Bar Attachment 1 2 3 4 5 6 - RATCHET WRENCH STRUT STABILIZER BAR LINK NUT STABILIZER BAR Fig. 35 Correctly Installed Stabilizer Bar To Cradle Bushing 1 - SWAY BAR ISOLATOR BUSHING 2 - SLIT IN SWAY BAR BUSHING 3 - SWAY BAR Fig. 34 Front Stabilizer Bar Retainers 1 2 3 4 5 - STEERING GEAR STABILIZER BAR RAISED BEAD FRONT CRADLE CROSSMEMBER RETAINERS INSTALLATION NOTE: Two different diameter stabilizer bars are available for this vehicle. Therefore, two different size bushings/cushions are also used. Use the correct bushing/cushion on the correct stabilizer bar. (2) Position stabilizer bar into front suspension cradle so stabilizer bar bushings are aligned with depressions in cradle. Install stabilizer bar bushing retainers onto crossmember aligning raised bead on retainer with cutouts in bushings (Fig. 36). Do not tighten Stabilizer bar bushing retainers bolts at this time. (3) Check position of the stabilizer bar in the front suspension cradle. The center of the curved section of the stabilizer bar must be aligned with the raised line in the center of the front suspension cradle (Fig. 37). (4) Install the stabilizer bar link mounting stud through the hole in each end of the stabilizer bar (Fig. 33). CAUTION: When installing the nut on the mounting stud of the stabilizer bar link, do not allow the stud to rotate in it’s socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud (Fig. 33). FRONT SUSPENSION RS 2 - 19 STABILIZER BAR (Continued) Fig. 36 Stabilizer Bar Bushing Retainer Installation 1 2 3 4 5 6 7 - SWAY BAR SWAY BAR BUSHING BUSHING SPLIT FRONT SUSPENSION CRADLE BUSHING CUT-OUT BUSHING RETAINER RAISED BEAD (6) Tighten the stabilizer bar bushing retainer to cradle attaching bolts (Fig. 34) to 68 N·m (50 ft. lbs.) torque. (7) Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember (Fig. 32). Tighten the M-14 size bolts to a torque of 153 N·m (113 ft. lbs.). Tighten the M-12 size bolts to a torque of 106 N·m (78 ft. lbs.). (8) Install the lower control arm rear bushing retainer bolts through reinforcement on each side of each lower control arm rear bushing. Tighten these M-10 size bolts to a torque of 61 N·m (45 ft. lbs.). (9) Install the two bolts and bushings attaching the reinforcement and rear of cradle crossmember to body of vehicle (Fig. 32). Tighten bolts to a torque of 163 N·m (120 ft. lbs.). (10) Install the power steering cooler (Fig. 31). Tighten bolts to a torque of 11 N·m (100 in. lbs.). (11) Lower the vehicle. STRUT DESCRIPTION - STRUT ASSEMBLY Fig. 37 Stabilizer Bar Correctly Positioned In Cradle 1 - RAISED BEAD 2 - SWAY BAR 3 - WHEN INSTALLING SWAY BAR THE RAISED BEAD ON THE SUSPENSION CRADLE MUST BE IN THE CENTER OF RADIUS IN SWAY BAR 4 - FRONT SUSPENSION CRADLE (5) Hand-thread the nut on the end of each stabilizer bar link stud. Hold the studs from turning by placing an open-end wrench on the flat machined into the link’s mounting stud, then tighten each nut while holding the wrench in place (Fig. 33). Tighten each nut to a torque of 88 N·m (65 ft. lbs.). A Macpherson type strut assembly is used in place of a conventional front suspension’s upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using two bolts and nuts going through the strut clevis bracket and steering knuckle. The top of the strut mounts directly to the strut tower of the vehicle using the threaded studs on the strut assemblies upper mount. The strut assembly includes the components listed in the figure (Fig. 38). Each component is serviced by removing the strut assembly from the vehicle and disassembling it. The coil springs are side-oriented. Springs on the left side of the vehicle have a left-hand wind top-tobottom while springs on the right side have a righthand wind top-to-bottom. This helps provide better vehicle stability during jounce and rebound maneuvers of the front suspension. Left and right springs must not be interchanged. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If the coil springs require replacement, be sure that the springs are replaced with springs meeting the correct load rating and spring rate for the vehicle and its specific options. OPERATION - STRUT ASSEMBLY The strut assembly cushions the ride of the vehicle, controlling vibration, along with jounce and rebound of the suspension. 2 - 20 FRONT SUSPENSION RS STRUT (Continued) Fig. 38 STRUT ASSEMBLY 1 2 3 4 5 - NUT UPPER MOUNT PIVOT BEARING UPPER SPRING SEAT UPPER SPRING ISOLATOR 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 seat and 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. During steering maneuvers, the strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint) turn as an assembly. DIAGNOSIS AND TESTING - STRUT ASSEMBLY (1) Inspect for damaged or broken coil springs (Fig. 38). (2) Inspect for torn or damaged strut assembly dust boots (Fig. 38). (3) Inspect the coil spring isolator on the lower spring seat for any signs of damage or deterioration. (4) Lift dust boot (Fig. 39) and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a 6 - COIL SPRING 7 - DUST SHIELD 8 - JOUNCE BUMPER 9 - LOWER SPRING ISOLATOR 10 - STRUT (DAMPER) stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly (Fig. 39). Also inspect jounce bumpers for signs of damage or deterioration. REMOVAL - STRUT ASSEMBLY WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED. (1) Raise the vehicle. See Hoisting in Lubrication and Maintenance. (2) Remove the wheel and tire assembly from location on front of vehicle requiring strut removal. (3) If both strut assemblies are to be removed, mark the strut assemblies right or left according to which side of the vehicle they were removed from. (4) Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets (Fig. 40). FRONT SUSPENSION RS 2 - 21 STRUT (Continued) open-end wrench on the flat machined into the link’s mounting stud, then remove the nut while holding the wrench in place. Push the stud out of the bracket. Fig. 39 Strut Assembly Leakage Inspection (Typical) 1 - DUST BOOT 2 - STRUT SHAFT 3 - STRUT FLUID RESERVOIR 4 - INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID LEAKAGE Fig. 41 Stabilizer Bar Link To Strut Attachment 1 - NUT 2 - STRUT 3 - STABILIZER BAR LINK CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. (6) Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Fig. 42). Fig. 40 Brake Hose And Speed Sensor Cable Routing 1 2 3 4 5 6 - STRUT DAMPER - WHEEL SPEED SENSOR CABLE - ROUTING BRACKET - HYDRAULIC BRAKE HOSE - ATTACHING BOLT - ROUTING BRACKET CAUTION: When removing the nut from the stud of the stabilizer bar link, do not allow the stud to rotate in it’s socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud (Fig. 41). (5) Remove the stabilizer bar link from the bracket on the strut assembly (Fig. 41). To do so, place an Fig. 42 Strut Damper Attachment To Steering Knuckle 1 2 3 4 5 - STRUT CLEVIS BRACKET - ATTACHING BOLTS - TIE ROD END - ROTOR - STEERING KNUCKLE 2 - 22 FRONT SUSPENSION RS STRUT (Continued) (7) Remove the 3 nuts attaching the strut assembly upper mount to the strut tower (Fig. 43) and remove the strut assembly from the vehicle. end of the coil spring, so the strut is held in place once the strut shaft nut is removed. Fig. 43 Strut Assembly To Strut Tower Attaching Nuts (Typical) 1 2 3 4 - WINDSHIELD WIPER MODULE STRUT TOWER STRUT MOUNT ATTACHING BOLTS UPPER STRUT MOUNT (8) To disassemble the strut assembly, (Refer to 2 SUSPENSION/FRONT/STRUT - DISASSEMBLY). DISASSEMBLY - STRUT ASSEMBLY 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 of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring. Follow the manufacturer’s instructions closely. WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. (1) Position the strut assembly in the strut coil spring compressor following the manufacturers instructions. Position the lower hooks on the coil spring first. The strut clevis bracket should be positioned straight outward from the compressor. (2) Turn the upper mount of the strut assembly toward the inside of the compressor as shown to allow positioning of the compressor upper hooks (Fig. 44). Position the upper hooks on top of the coil spring upper seat approximately 1 inch from outside diameter of seat (Fig. 47). Do not allow hooks to be placed closer to edge. Place a clamp on the lower Fig. 44 Mount Rotated And Hooks Positioned 1 - UPPER MOUNT TURNED TOWARD COMPRESSOR 2 - COMPRESSOR UPPER HOOKS 3 - UPPER SPRING SEAT (3) Compress the coil spring until all coil spring tension is removed from the upper mount. (4) Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut (Fig. 45). Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. (5) Remove the upper mount from the strut shaft. (6) If the pivot bearing needs to be serviced, remove it from the top of the coil spring upper seat by pulling it straight up. (7) Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring. NOTE: If the coil spring or upper spring seat needs to be serviced, proceed with the next step, otherwise, proceed with step 10. (8) Release the tension from the coil spring by backing off the compressor drive fully. Push back the compressor upper hooks and remove the upper spring seat with upper spring isolator. (9) Remove the coil spring from the spring compressor. (10) Remove the dust shield and jounce bumper as an assembly from the strut shaft by pulling both straight up and off the strut shaft. The dust shield cannot be separated from the jounce bumper until after it is removed from strut shaft. RS FRONT SUSPENSION 2 - 23 STRUT (Continued) NOTE: Coil Springs on this vehicle are side-oriented. Springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right-hand wind top-to-bottom. Left and right springs must not be interchanged. NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with step 5. Fig. 45 Retaining Nut Removal/Installation (Typical) (1) Place the coil spring in the compressor lower hooks following the manufacturers instructions. Proper orientation of the spring to the strut (once installed) is necessary. Consider the following when placing the coil spring in the compressor: From above, the compressor back is at the 12 o’clock position, and you, standing in the front of the machine, are at the 6 o’clock position. Place the lower coil spring end at the 6 o’clock position for both left and right springs. (Fig. 46). 1 - UPPER MOUNT 2 - SPECIAL TOOL 6864 (11) Remove the jounce bumper from the dust shield. The jounce bumper is removed from the dust shield by collapsing the dust shield until the jounce bumper can be pulled free from the dust boot. (12) Remove the spring isolator from the lower spring seat on the strut (Fig. 38). (13) Inspect the strut assembly components (Fig. 38) for the following and replace as necessary: • Inspect the strut for any condition of shaft binding over the full stroke of the shaft. • Check the upper mount for cracks and distortion and its retaining studs for any sign of damage. • Check the upper seat for stress cracks and wear. • Check the upper spring isolator for severe deterioration. • Check for binding of the strut assembly pivot bearing. • Inspect the dust shield for rips and deterioration. • Inspect the jounce bumper for cracks and signs of deterioration. ASSEMBLY - STRUT ASSEMBLY For the disassembly and assembly of the strut assembly, use of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring. Follow the manufacturer’s instructions closely. Fig. 46 Spring Positioned In Compressor (Right Spring Shown) 1 - COMPRESSOR LOWER HOOKS 2 - COIL SPRING END (2) Install the upper seat and upper isolator on top of the coil spring. Position the notch in the perimeter of the upper seat toward the front of the compressor (same 6 o’clock position as in step 1). (3) Position the upper hooks on top of the coil spring upper seat so the upper hooks span approximately 1 inch past outside diameter of upper seat (Fig. 47). This will allow proper clearance for upper mount installation without pinching the hooks in-between the two pieces. Do not allow hooks to be placed closer to edge. (4) Compress the coil spring far enough to allow strut installation. 2 - 24 FRONT SUSPENSION RS STRUT (Continued) slot on the jounce bumper. The jounce bumper will be at the top of the inner dust boot. Return the dust shield to its fully extended length. (9) Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. The clevis bracket on the strut should point straight outward away from the compressor (to the 6 o’clock position). This position should be within 5° of the lower end tip of the coil spring (Fig. 49). If necessary, reposition the strut or coil spring in the compressor so both of these line up straight outward away from the compressor (to the 6 o’clock position). Install the clamp to hold the strut and coil together. Fig. 47 Hook Placement On Upper Seat 1 - HOOKS POSITIONED 1 INCH FROM EDGE 2 - PIVOT BEARING AND UPPER SEAT (5) If the pivot bearing has been removed from the upper seat, install the pivot bearing on the top of the upper spring seat (Fig. 48). The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat. Be sure the pivot bearing is sitting flat on the spring seat once mounted. Fig. 49 Coil Spring Positioning 1 2 3 4 5 Fig. 48 Pivot Bearing Installation 1 - PIVOT BEARING 2 - UPPER SEAT (6) Install the spring isolator on the lower spring seat of the strut (Fig. 38). (7) Install the jounce bumper on the strut shaft (Fig. 38). The jounce bumper is to be installed with the small end pointing downward. (8) Install the dust shield on the strut. Collapse and stretch the dust shield down over the top of the jounce bumper until the dust shield snaps into the - FRONT OF VEHICLE END OF RIGHT COIL SPRING AT STRUT LOWER SEAT LOWER SEATS OF STRUTS STRUT CLEVIS BRACKETS END OF LEFT COIL SPRING AT STRUT LOWER SEAT (10) Install the strut mount over the strut shaft and onto the top of the pivot bearing and upper seat as shown (Fig. 44). Loosely install the retaining nut on the strut shaft. (11) Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut (Fig. 45). Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 100 N·m (75 ft. lbs.). NOTE: Before releasing the tension the compressor has on the spring, using the following figure as reference (Fig. 50), make sure the upper spring seat, coil spring and strut clevis bracket are all lined up properly (within 5° of one another). FRONT SUSPENSION RS 2 - 25 STRUT (Continued) 43). Then using a crow foot. tighten the 3 attaching nuts to a torque of 28 N·m (250 in. lbs.). CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. NOTE: The strut clevis-to-steering knuckle bolts are installed differently on each side of the vehicle. Left hand side bolts are to be installed from vehicle rear to front. Right side bolts are to be installed from vehicle front to rear. Fig. 50 Components Lined Up 1 2 3 4 - IMAGINARY VERTICAL LINE CLEVIS BRACKET END OF COIL SPRING NOTCH IN UPPER SPRING SEAT (12) Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat are align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. (13) Install strut assembly on the vehicle. (Refer to 2 - SUSPENSION/FRONT/STRUT - INSTALLATION) INSTALLATION - STRUT ASSEMBLY CAUTION: Front strut coil springs are side-oriented. When installing a strut assembly, make sure the strut being installed has the correct coil spring for that side of the vehicle. Springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right-hand wind top-to-bottom (Fig. 49). Do not interchange the two sides. (1) Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in shock tower. Install the 3 upper strut mount attaching nut/washer assemblies (Fig. (2) Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Fig. 42). If strut assembly is attached to steering knuckle using a cam bolt, the cam bolt must be installed in the lower slotted hole on strut clevis bracket. Tighten the strut clevis-to-steering knuckle attaching bolts to a torque of 81 N·m (60 ft. lbs.) plus an additional 1/4 (90°) turn after specified torque is met. (3) Install the stabilizer bar link mounting stud through the bracket on the strut assembly (Fig. 41). CAUTION: When installing the nut on the mounting stud of the stabilizer bar link, do not allow the stud to rotate in it’s socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud (Fig. 41). (4) Hand thread the nut on the end of the stabilizer bar link stud. Hold the stud from turning by placing an open-end wrench on the flat machined into the link’s mounting stud, then tighten the nut while holding the wrench in place (Fig. 41). Tighten the nut to a torque of 88 N·m (65 ft. lbs.). (5) Install the hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets (Fig. 40). Tighten the routing bracket attaching bolts to a torque of 13 N·m (10 ft. lbs.). (6) Install the wheel/tire assembly on the vehicle. (7) Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). 2 - 26 REAR SUSPENSION RS REAR SUSPENSION TABLE OF CONTENTS page REAR SUSPENSION DESCRIPTION - REAR SUSPENSION ..... OPERATION - REAR SUSPENSION . . . . . . . SPECIFICATIONS REAR SUSPENSION FASTENER TORQUE SPECIAL TOOLS REAR SUSPENSION . . . . . . . . . . . . . . . . . BUSHINGS REMOVAL - LEAF SPRING FRONT BUSHING INSTALLATION - LEAF SPRING FRONT BUSHING ......................... HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - HUB AND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . JOUNCE BUMPER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - AWD AND HEAVY DUTY .... REMOVAL - FRONT-WHEEL-DRIVE ..... INSTALLATION INSTALLATION - AWD AND HEAVY DUTY . INSTALLATION - FRONT-WHEEL-DRIVE . . SHOCK ABSORBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - SHOCK ABSORBER . . . . . . . . . DISASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . 27 . . 28 . . 28 . 29 . . 29 . . 30 . . 31 . . 31 . . 31 . . 33 . . 36 . . 36 . . 36 . . 36 . . 36 . . 36 . . 37 . . 37 . . 37 . . 37 REAR SUSPENSION DESCRIPTION - REAR SUSPENSION The rear suspension design on this vehicle uses leaf springs, and a tube and casting axle (Fig. 1) (Fig. 2). The leaf springs used on the rear suspension of this vehicle are of either a mono-leaf or multi-leaf design. There are 2 different rear suspension designs available: • Front-Wheel-Drive • All-Wheel-Drive The rear axle used on Front-Wheel-Drive applications of this vehicle is mounted to the rear leaf page ASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - SHOCK ABSORBER . . . SPRING - AWD DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL - AWD . . . . . . . . . . . . . . . . . . INSTALLATION - AWD . . . . . . . . . . . . . . . SPRING - FWD DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL - FWD . . . . . . . . . . . . . . . . . . INSTALLATION - FWD .............. SPRING MOUNTS - FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . SPRING MOUNTS - REAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . STABILIZER BAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - AWD . . . . . . . . . . . . . . . . . REMOVAL - FWD ................ INSTALLATION INSTALLATION - AWD . . . . . . . . . . . . . INSTALLATION - FWD . . . . . . . . . . . . . TRACK BAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38 . . . . . 38 . . . . . . . . . . . . . . . . . 38 . 38 . 38 . 39 . . . . . . . . . . . . . . . . . 40 . 40 . 40 . 41 . . . . . 42 . . . . . 43 . . . . . 43 . . . . . 44 . . . . . 44 . . . . . 44 . . . . . 44 . . . . . 44 . . . . . 44 . . . . . 45 . . . . . . . . . . . . . . . . . 45 . 45 . 45 . 45 springs using isolator bushings at the axle mounting brackets. The rear axle used on All-Wheel-Drive applications of this vehicle is also mounted to the rear leaf springs, but does not use isolator bushings between the rear axle and the leaf springs. Each side of the rear suspension consists of these major components: • Leaf spring • Jounce bumper • Shock absorber • Hub and bearing • Track bar (one per suspension) • Stabilizer bar (one per suspension) REAR SUSPENSION RS 2 - 27 REAR SUSPENSION (Continued) Fig. 1 Front-Wheel-Drive Rear Suspension 1 2 3 4 5 6 - SHACKLE REAR MOUNT (HANGER) TRACK BAR SPRING PLATE ISOLATOR FRONT MOUNT (HANGER) 7 - LEAF SPRING (MONO-LEAF) 8 - ISOLATOR 9 - FWD REAR AXLE 10 - STABILIZER BAR LINKS 11 - STABILIZER BAR OPERATION - REAR SUSPENSION This rear suspension is designed to handle the various load requirements of the vehicle yet allow for a comfortable ride. The rear wheel bearings used are similar to the bearings used in the front suspension. A hub and bearing assembly is used. Fig. 2 All-Wheel-Drive Rear Suspension 1 2 3 4 - SHACKLE - REAR MOUNT (HANGER) - LEAF SPRING (MULTI-LEAF) - AWD REAR AXLE 2 - 28 REAR SUSPENSION RS REAR SUSPENSION (Continued) SPECIFICATIONS SPECIAL TOOLS REAR SUSPENSION FASTENER TORQUE REAR SUSPENSION N·m Ft. Lbs. In. Lbs. Hub And Bearing Mounting Bolts 129 95 — Hub And Bearing Axle Hub Nut 244 180 — Jounce Bumper Mounting Bolt 33 24 290 Leaf Spring Front Mount-ToBody Bolts 61 45 — Leaf Spring Front Pivot Bolt 156 115 — Leaf Spring Plate-To-Axle Bolts 95 70 — Leaf Spring Rear Mount-ToBody Bolts 61 45 — Leaf Spring Shackle Plate Nuts 61 45 — Shock Absorber Mounting Bolts 88 65 — Stabilizer Bar Bushing Retainer Bolts 61 45 — Stabilizer Bar Link Nuts 61 45 — Stabilizer Bar Link Frame Bracket Mounting Bolts 61 45 — Track Bar Bracket-To-Body Mount Bolts 61 45 — Track Bar Pivot Bolts 95 70 — Wheel Mounting (Lug) Nut 135 100 — DESCRIPTION Remover, Hub/Bearing 8458 Remover/Installer, Bushing 8459 Remover/Installer, Bushing 8526 Press, Ball Joint C-4212F REAR SUSPENSION RS BUSHINGS REMOVAL - LEAF SPRING FRONT BUSHING (1) Raise vehicle on frame-contact hoist as follows: (a) Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown (Fig. 3). (b) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (c) Raise the vehicle to a comfortable working level. 2 - 29 it enough to allow access to spring pivot bolt. It may be necessary to place a wooden block between the spring and vehicle to hold forward end of the spring in place. (6) Remove leaf spring forward pivot bolt, then remove mounting bracket. (7) Straighten the retainer tabs on the bushing (Fig. 4). Fig. 4 STRAIGHTENED RETAINING TABS 1 - SPRING EYE 2 - RETAINING TABS Fig. 3 LIFTING POINT AND SPRING MOUNT 1 2 3 4 5 6 - BODY SILL AREA MOUNTING BOLTS SPRING MOUNTING BRACKET LEAF SPRING HOIST LIFT ARM WOODEN BLOCK (2) Position an under-hoist utility jack or transmission jack under rear axle toward the side needing bushing replacement. Jack pad should just contact axle. (3) Remove shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). (4) Remove four bolts securing leaf spring front mounting bracket to the body (Fig. 3). (5) Using jack, slowly lower rear axle, permitting the forward end of rear spring to hang down. Lower (8) Place Remover/Installer, Special Tool 8459 on leaf spring and bushing as shown (Fig. 5) and tighten Set Screw securing Remover Plate to tool threaded shaft. (9) Tighten nut (Fig. 5), removing bushing from spring eye. (10) Remove the tool from spring, then remove bushing from tool. INSTALLATION - LEAF SPRING FRONT BUSHING (1) Install by hand NEW bushing in left side of leaf spring eye. (2) Place Remover/Installer, Special Tool 8459 on leaf spring and bushing as shown (Fig. 6) and tighten Set Screw securing Installer Plate (8459–3) to tool threaded shaft. (3) Tighten nut (Fig. 6), installing bushing in spring eye. Tighten nut until there is approximately a 1 mm gap between the bushing flange and the spring eye. Do not bottom the flange against the spring eye. (4) Remove Remover/Installer from the bushing and leaf spring. (5) Bend the retainer tabs on bushing outward against spring eye. 2 - 30 REAR SUSPENSION RS BUSHINGS (Continued) Fig. 5 TOOL 8459 MOUNTED FOR BUSHING REMOVAL 1 2 3 4 5 6 7 8 - BUSHING BEARING WASHER NUT BODY (8459-1) PIN REMOVER PLATE (8459-2) SET SCREW Fig. 6 TOOL 8459 MOUNTED FOR BUSHING INSTALLATION 1 2 3 4 5 6 7 8 - NUT WASHER BEARING LEAF SPRING EYE BUSHING INSTALLER PLATE (8459-3) PIN BODY (8459-1) (6) Position spring mounting bracket over spring eye and install pivot bolt through center of bushing from the outboard side. (12) Tighten the lower shock absorber mounting bolt to 88 N·m (65 ft. lbs.) torque. NOTE: The pivot bolt must be installed from the outboard side to allow proper bracket to body mounting. HUB / BEARING (7) Install the nut on the pivot bolt and lightly tighten. Do not fully tighten bolt at this time. (8) Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into place against the body. It may help to use a drift punch placed through the hole centered between the mounting bolt holes in the bracket and the pilot hole in the body of the vehicle as a guide. When the four mounting bolt holes line up with their threads in the body, Install the mounting bolts (Fig. 3). Tighten the four mounting bolts to 61 N·m (45 ft. lbs.) torque. (9) Raise or lower the jack until shock absorber lower eye aligns with threads in axle housing. Install shock absorber lower mounting bolt. Do not fully tighten bolt at this time. (10) Lower the vehicle and remove hoist arms and block of wood from under vehicle. (11) Tighten the spring front pivot bolt to 156 N·m (115 ft. lbs.) torque. DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one-piece sealed unit, or hub and bearing unit type assembly (Unit III). The hub and bearing is mounted to the center of the rear axle using 4 mounting bolts. It has five wheel mounting studs on the hub flange. All-Wheel-Drive vehicles have a hub and bearing unit with a splined hole in the center of the hub for rear driveshaft stub axle acceptance. Front-Wheel-Drive vehicles with antilock brakes have an internally mounted wheel speed sensor and tone wheel. This hub and bearing can be identified by the rounded cap and molded in connector on the rear of the assembly (Fig. 7). The sensor and tone wheel cannot be serviced separately from the hub and bearing. REAR SUSPENSION RS 2 - 31 HUB / BEARING (Continued) REMOVAL FRONT-WHEEL-DRIVE VEHICLES Fig. 7 Hub And Bearing - FWD With ABS OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the tire and wheel assembly (and driveshaft on All-Wheel-Drive vehicles). The five wheel mounting studs mount the tire and wheel assembly, and disc brake rotor or brake drum to the vehicle. On All-Wheel-Drive vehicles, the splined mating of the driveshaft stub axle and hub allows the driveshaft to rotate with the hub and wheel. Front-Wheel-Drive vehicles equipped with antilock brakes have a wheel speed sensor and tone wheel mounted to the rear of the hub and bearing. The tone wheel rotates with the hub which is sensed by the wheel speed sensor. (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove wheel and tire. (Refer to 22 - TIRES/ WHEELS - REMOVAL) (3) Remove brake drum or disc brake caliper and rotor from hub and bearing. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/DRUM - REMOVAL)(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ ROTOR - REMOVAL) (4) If equipped with antilock brakes, perform the following: (a) Remove secondary (yellow) retaining clip at rear of wheel speed sensor head (Fig. 8). (b) Push up on metal retaining clip (Fig. 8) until it bottoms. This will release wheel speed sensor head from hub and bearing. (c) While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. DIAGNOSIS AND TESTING - HUB AND BEARING The bearing contained in the hub and bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Fig. 8 Sensor Connector At Hub And Bearing 1 - SECONDARY SENSOR RETAINING CLIP 2 - METAL SENSOR RETAINING CLIP 3 - HUB AND BEARING (5) Remove the 4 bolts attaching the hub and bearing to the rear axle. CAUTION: Corrosion may occur between the hub and bearing, and the axle. If this occurs the hub and bearing will be difficult to remove from the axle. If the hub and bearing will not come out of the axle by pulling on it by hand, do not pound on the hub and bearing to remove it from the axle. Damage will occur. Use the following procedure. 2 - 32 REAR SUSPENSION RS HUB / BEARING (Continued) (6) If hub and bearing cannot be removed from the axle by hand, use Remover, Special Tool 8458 (Fig. 9) and following procedure to press the hub and bearing out of the axle. Fig. 9 Removal Using Special Tool 8458 1 2 3 4 5 6 - THREADED GUIDE PINS 8458-4 HUB AND BEARING LEAF SPRING PLATE FORCING SCREW 8458-3 SCREW MOUNT 8458-2 PUSH PLATE 8458-1 (a) Thread Threaded Guide Pins into hub and bearing mounting bolt holes. (b) Remove the two outboard spring plate bolts. (c) Using the spring plate bolts, install the Screw Mount, Special Tool 8458–2, as shown (Fig. 9). (d) Place Push Plate, Special Tool 8458–1, on ends of Threaded Guide Pins (e) Place a dab of grease in dimple of Push Plate. (f) Tighten the Forcing Screw, Special Tool 8458–3, up against dimple in Push Plate and press hub and bearing out of axle by continuing to tighten screw. (g) Remove the tool. (h) Reinstall the two outboard spring plate bolts. Tighten the bolts to 102 N·m (75 ft. lbs.) torque. (7) Remove the hub/bearing from the rear axle and brake support plate. ALL-WHEEL-DRIVE VEHICLES (1) Set the parking brake. The parking brake is set to keep the hub and bearing, and axle shaft from rotating when loosening the hub nut. (2) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (3) Remove the wheel/tire assembly. (Refer to 22 TIRES/WHEELS - REMOVAL) (4) Remove the cotter pin and nut retainer (Fig. 18) from the stub shaft of the outer C/V joint. (5) Remove the spring washer (Fig. 17) from the stub shaft of the outer C/V joint. (6) Remove the hub nut and washer (Fig. 16) from the stub shaft of the outer C/V joint. (7) Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear drive line module. (8) Remove the rear wheel speed sensor (Fig. 19) from the rear hub/bearing. (9) Release the parking brake. (10) Remove the disc brake caliper to adapter guide pin bolts (Fig. 15). (11) Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter (Fig. 14). (12) Support caliper to prevent the weight of the caliper from damaging the flexible brake hose (Fig. 10). Fig. 10 Correctly Supported Caliper 1 2 3 4 5 - WIRE - CALIPER - ADAPTER - ROTOR - INNER FENDER (13) Remove the rotor from the hub/bearing. (14) Remove driveshaft from rear drive line module and hub/bearing. Driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the drive line module. Then, slide REAR SUSPENSION RS 2 - 33 HUB / BEARING (Continued) the outer joint of the driveshaft out of the hub/bearing. (15) Remove the hub/bearing to axle mounting bolts (Fig. 13). CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/ bearing will not come out of the axle by pulling on it by hand, do not pound on the hub/bearing to remove it from the axle. Pounding on the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in noise or failure of the hub/bearing. To remove a hub/bearing which is corroded to the axle, lightly tap the disc brake caliper adapter using a soft faced hammer. This will remove both the disc brake caliper adapter and hub/bearing from the axle. The hub/bearing will then need to be removed from the caliper adapter. (16) Remove the hub/bearing from the axle. (Fig. 12). (17) If the disc brake caliper adapter and hub/ bearing were removed as an assembly from the axle and the hub/bearing cannot be removed from the adapter by hand, use the following procedure to remove it from the adapter. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of hub/bearing (Fig. 11). Do not position special tool on inner race of hub/bearing. Lightly strike Remover, Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. INSTALLATION FRONT-WHEEL-DRIVE VEHICLES (1) Install the 4 hub and bearing to axle mounting bolts into the holes in the flange of the rear axle. (2) Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. (3) Align the rear hub and bearing with the 4 mounting bolts and start mounting bolts into hub and bearing. Tighten the 4 bolts in a crisscross pattern until the hub and bearing and brake support plate is fully and squarely seated onto flange of rear axle. Tighten the 4 mounting bolts to a torque of 129 N·m (95 ft. lbs.) NOTE: If equipped with antilock brakes, make sure wheel speed sensor stays clean and dry as it is installed into the hub and bearing cap. (4) If the vehicle is equipped with antilock brakes, perform the following: (a) If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. (b) Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. (c) Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side (Fig. 8). (5) Install brake drum or disc brake rotor and brake caliper. (Refer to 5 - BRAKES/HYDRAULIC/ MECHANICAL/DRUM - INSTALLATION)(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR INSTALLATION) (6) Install wheel and tire (Refer to 22 - TIRES/ WHEELS - INSTALLATION). Tighten the wheel nuts in the proper sequence to a torque of 135 N·m (100 ft. lbs.). (7) Adjust the rear brakes as necessary. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - ADJUSTMENTS) (8) Lower vehicle. (9) Road test vehicle to ensure proper operation of brakes. ALL-WHEEL-DRIVE VEHICLES Fig. 11 Hub/Bearing Removal From Caliper Adapter 1 2 3 4 - SPECIAL TOOL 8214-1 PARK BRAKE CABLE DISC BRAKE CALIPER ADAPTER HUB/BEARING (1) Install hub/bearing on end of axle. (Fig. 12). (2) Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 hub/ bearing mounting bolts (Fig. 13) until the disc brake caliper adapter and hub/bearing are squarely seated against the axle. Then tighten the hub/bearing mounting bolts to a torque of 129 N·m (95 ft. lbs.). 2 - 34 REAR SUSPENSION RS HUB / BEARING (Continued) Fig. 14 Removing/Installing Caliper (Left Side Shown) Fig. 12 Hub/Bearing Removal And Installation 1 - PARK BRAKE BRAKE SHOE 2 - HUB/BEARING 3 - PARK BRAKE BRAKE SHOE 1 2 3 4 5 6 7 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST - DISC BRAKE CALIPER - ADAPTER ABUTMENT - OUTBOARD BRAKE SHOE HOLD DOWN CLIP - OUTBOARD BRAKE SHOE - ROTOR - ADAPTER CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts. (6) Install the disc brake caliper guide pin bolts (Fig. 15). Tighten the guide pin bolts to a torque of 35 N·m (26 ft. lbs.). Fig. 13 Hub/Bearing Mounting Bolts 1 2 3 4 - HUB/BEARING - AXLE - MOUNTING BOLTS - CALIPER ADAPTER (3) Install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft the drive line module. (4) Install rotor on hub/bearing. (5) Carefully lower disc brake caliper and brake shoes over rotor and onto caliper adapter by reversing the removal procedure (Fig. 14). Fig. 15 Caliper Guide Pin Bolts 1 2 3 4 5 - STUD PIN BOLTS - DISC BRAKE CALIPER - DRIVESHAFT - AXLE - DISC BRAKE CALIPER ADAPTER REAR SUSPENSION RS 2 - 35 HUB / BEARING (Continued) (7) Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut (Fig. 16) on the stub shaft of the outer C/V joint. Fig. 17 Spring Washer 1 2 3 4 - HUB NUT STUB SHAFT ROTOR SPRING WASHER 1 2 3 4 5 - CALIPER COTTER PIN ROTOR NUT RETAINER OUTER C/V JOINT Fig. 16 Hub Nut And Washer 1 2 3 4 5 - CALIPER - HUB NUT - WASHER - ROTOR - ADAPTER (8) Lower vehicle. (9) Set the park brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting nuts. (10) Raise vehicle. (11) Tighten the driveshaft inner joint to drive line module output shaft mounting bolts to a torque of 61 N·m (45 ft. lbs.). (12) Tighten the outer C/V joint hub nut (Fig. 16) to a torque of 244 N·m (180 ft. lbs.). (13) Install the spring washer (Fig. 17) on the stub shaft of the outer C/V joint. (14) Install the nut retainer and cotter pin (Fig. 18) on the stub shaft of the outer C/V joint. (15) Install the wheel speed sensor on the hub/ bearing and adapter. Install the wheel speed sensor attaching bolt (Fig. 19). Tighten the wheel speed sensor attaching bolt to a torque of 12 N·m (105 in. lbs). (16) Install wheel and tire. (Refer to 22 - TIRES/ WHEELS - INSTALLATION) (17) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (18) Lower vehicle. Fig. 18 Cotter Pin And Nut Retainer CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. 2 - 36 REAR SUSPENSION RS HUB / BEARING (Continued) Fig. 19 Wheel Speed Sensor 1 - MOUNTING BOLT 2 - WHEEL SPEED SENSOR Fig. 20 Jounce Bumper 1 - JOUNCE BUMPER (19) Road test vehicle to ensure proper operation of the brake system. JOUNCE BUMPER DESCRIPTION There are two jounce bumpers used in the rear suspension. One mounts to each frame rail above the rear axle. OPERATION The jounce bumper limits suspension travel and metal-to-metal contact of the rear axle with the frame under full jounce conditions. Fig. 21 Jounce Bumper - FWD REMOVAL REMOVAL - AWD AND HEAVY DUTY (1) Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise (Fig. 20). (2) Remove the jounce bumper from the frame rail. REMOVAL - FRONT-WHEEL-DRIVE (1) Remove the bolt attaching the jounce bumper to frame rail (Fig. 21). (2) Remove the jounce bumper from the frame rail. 1 - JOUNCE BUMPER INSTALLATION INSTALLATION - AWD AND HEAVY DUTY (1) Install jounce bumper through bumper support plate and thread into welded nut in frame rail. (2) Tighten the jounce bumper to 33 N·m (290 in. lbs.) torque. INSTALLATION - FRONT-WHEEL-DRIVE (1) Hook the forward end of the jounce bumper bracket in the mounting hole of the frame rail, then install the mounting bolt in the opposite end, securing the bumper to the frame rail. Tighten the jounce bumper mounting bolt to 33 N·m (290 in. lbs.) torque. REAR SUSPENSION RS SHOCK ABSORBER 2 - 37 Tool 8526-2, on the tip of the Ball Joint Press screw drive as shown (Fig. 22). DESCRIPTION There is one shock absorber on each side of the rear suspension. The top of each shock absorber is bolted to the frame rail. The bottom of each shock absorber is bolted to the rear axle. This vehicle is available with either standard type or load-leveling shock absorbers. On the exterior, load-leveling shock absorbers are larger in diameter than standard shock absorbers. The load-leveling shock absorbers mount the same as the standard shock absorbers. OPERATION The shock absorber dampens jounce and rebound motions of the spring and suspension. Each load-leveling shock absorber is a self-leveling, self-contained vehicle leveling system and shock absorber combined. It does not require an external compressor, hoses, or height leveling sensors. All the height leveling sensors, hydraulic pump, etc., are contained inside the shock absorber. It uses road inputs (bumps, stops, starts, turns, acceleration, deceleration, etc.) to activate pumping, which results in the extension and compression of the shock absorber. REMOVAL - SHOCK ABSORBER Fig. 22 Special Tools Positioned For Removal 1 - SCREW DRIVE NOTE: It works well to place the Ball Joint Press, Special Tool C-4212F, in a bench vise as shown (Fig. 22) to perform this procedure. (3) Place the shock absorber upper mounting eye in the Receiver so the notch in the Receiver clears the shock absorber body (Fig. 23). (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Support the rear axle of the vehicle using 2 jackstands positioned at the outer ends of the axle. NOTE: If the shock absorber lower mounting bolt deflects upward during removal, raise axle by adjusting the support jack. If the lower shock absorber bolt deflects downward during removal, lower the axle by adjusting the support jack. (3) Remove the shock absorber lower mounting bolt. (4) While holding shock absorber, remove the shock absorber upper mounting bolt and shock absorber. DISASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) NOTE: This procedure applies to load-leveling shock absorbers only. (1) Remove the shock absorber from the vehicle. (2) Install the Receiver, Special Tool 8526-1, into the cup of the Ball Joint Press, Special Tool C-4212F, and tighten the set screw. Install the Driver, Special Fig. 23 Removing Bushing From Shock Absorber 1 - SCREW DRIVE 2 - SHOCK ABSORBER 3 - NOTCH (4) Tighten the screw drive until the Driver contacts the outer circumference of the bushing evenly (Fig. 23). Continue to tighten the screw drive until the bushing is pressed completely out of the shock absorber eye and into the Receiver. (5) Back off the screw drive and remove the bushing from the Receiver. 2 - 38 REAR SUSPENSION RS SHOCK ABSORBER (Continued) ASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) NOTE: This procedure applies to load-leveling shock absorbers only. (1) Install the Receiver, Special Tool 8526-1, into the cup of the Ball Joint Press, Special Tool C-4212F, and tighten the set screw. Install the Driver, Special Tool 8526-2, on the tip of the Ball Joint Press screw drive as shown (Fig. 24). Position the Driver this way to seat the bushing to its correct depth. Fig. 25 Installing Bushing In Shock Absorber 1 2 3 4 - BUSHING SCREW DRIVE SHOCK ABSORBER NOTCH (5) Tighten the upper and lower shock absorber mounting bolt to a torque of 88 N·m (65 ft. lbs.). SPRING - AWD Fig. 24 Special Tools Positioned For Installation 1 - SCREW DRIVE (2) Place the shock absorber upper mounting eye in the Receiver so the notch in the Receiver clears the shock absorber body (Fig. 25). (3) Position the bushing between the shock absorber eye and the Driver (Fig. 25). Tighten the screw drive until the Driver, bushing, and shock absorber eye are touching and squarely aligned. (4) Press the bushing into the shock absorber eye until the Driver bottoms against the face of the eye. (5) Back off the Ball Joint Press screw drive and remove the shock absorber from the press. (6) Install the shock absorber on the vehicle. Refer to REMOVAL AND INSTALLATION in this section for the procedure. INSTALLATION - SHOCK ABSORBER (1) While holding shock absorber in position against the frame rail, install the shock absorber upper mounting bolt. (2) Install the shock absorber lower mounting bolt securing the lower end of the shock absorber to the axle. (3) Remove the support jack. (4) Lower the vehicle to the ground so the full curb weight of the vehicle is supported by the suspension. DESCRIPTION The leaf springs used on the rear suspension of this vehicle are of either a mono-leaf or multi-leaf design depending on model and options. Since the rear springs come in various designs and rates, be sure the correct spring is in use. OPERATION The leaf spring controls ride quality and maintains ride height. REMOVAL - AWD (1) Raise vehicle on frame-contact hoist as follows: (a) Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown (Fig. 26). (b) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (c) Raise the vehicle to a comfortable working level. (2) Position an under-hoist utility jack or transmission jack under rear axle toward the side needing spring replacement. Jack pad should just contact axle. REAR SUSPENSION RS 2 - 39 SPRING - AWD (Continued) (4) Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove the weight of the axle from the rear springs. (5) Loosen and remove the axle plate bolts from the rear axle (Fig. 28). Fig. 26 LIFTING POINT AND SPRING MOUNT 1 2 3 4 5 6 - BODY SILL AREA MOUNTING BOLTS SPRING MOUNTING BRACKET LEAF SPRING HOIST LIFT ARM WOODEN BLOCK NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). (3) Begin removal of the shock absorber lower mounting bolt (Fig. 27). Fig. 28 Axle Plate Bolts 1 2 3 4 - LEAF SPRING - AXLE PLATE BOLTS (4) - AXLE PLATE - AXLE (6) Using the jack stands slowly lower the rear axle, permitting the rear springs to hang free. (7) Loosen and remove the 4 bolts at the front mount of the rear leaf spring (Fig. 26). (8) Loosen and remove the 2 bolts and the 2 pin nuts from the spring shackle for the rear leaf spring (Fig. 29). Then remove the inner half of the spring shackle from the outer half hanger of the spring hanger and the spring. (9) Remove the rear leaf spring from the outer half of the spring shackle. (10) Remove the leaf spring from the vehicle. (11) Loosen and remove the pivot bolt from the front mount of the rear leaf spring. (Fig. 30). INSTALLATION - AWD CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring. Fig. 27 Rear Shock Absorber Mounting Bolt 1 - SHOCK BOLT (1) Install the front eyelet of the rear leaf spring into the spring mount. Install the pivot bolt and nut. Do not tighten the pivot bolt at this time. (2) Position the front spring mount for the rear leaf spring against the floor pan of the vehicle. Install the 4 mounting bolts for the front spring mount (Fig. 26). Tighten the 4 mounting bolts to a torque of 61 N·m (45 ft. lbs.). 2 - 40 REAR SUSPENSION RS SPRING - AWD (Continued) CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque shown below. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the torque specification listed below. This sequence must be followed to properly seat the bushings into the springs and to avoid bending the spring hanger. Fig. 29 All-Wheel-Drive Rear Suspension 1 2 3 4 - SHACKLE - REAR MOUNT (HANGER) - LEAF SPRING (MULTI-LEAF) - AWD REAR AXLE (8) Tighten the spring front pivot bolt to 156 N·m (115 ft. lbs.) torque. (9) Tighten rear spring shackle pin nuts to 61 N·m (45 ft. lbs.) torque. (10) Tighten rear spring shackle inner to outer half retaining bolts to 61 N·m (45 ft. lbs.) torque. (11) Tighten the lower shock absorber mounting bolt to 102 N·m (75 ft. lbs.) torque. SPRING - FWD DESCRIPTION The leaf springs used on the rear suspension of this vehicle are of either a mono-leaf or multi-leaf design depending on model and options. Since the rear springs come in various designs and rates, be sure the correct spring is in use. OPERATION The leaf spring controls ride quality and maintains ride height. REMOVAL - FWD Fig. 30 Leaf Spring Front Mount (Typical) 1 - LEAF SPRING 2 - SPRING MOUNT (3) Install the rear of the leaf spring onto the outer half of the rear shackle. Install the inner half of the rear hanger. Install the pin nuts and bolts on the rear shackle, but do not tighten at this time. (4) Raise axle assembly into correct position with axle centered under spring locator post. (5) Install axle plate bolts (Fig. 28). Tighten bolts to 95 N·m (70 ft. lbs.) torque. (6) Install shock absorber bolts. Do not tighten at this time. (7) Lower the vehicle and remove hoist arms and block of wood from under vehicle. (1) Raise vehicle on frame-contact hoist as follows: (a) Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown (Fig. 31). (b) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (c) Raise the vehicle to a comfortable working level. (2) Position an under-hoist utility jack or transmission jack under rear axle toward the side needing spring replacement. Jack pad should just contact axle. (3) Remove the shock absorber lower mounting bolt (Fig. 32). NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). REAR SUSPENSION RS 2 - 41 SPRING - FWD (Continued) Fig. 33 Spring Plate Bolts 1 - SPRING PLATE Fig. 31 LIFTING POINT AND SPRING MOUNT 1 2 3 4 5 6 - BODY SILL AREA MOUNTING BOLTS SPRING MOUNTING BRACKET LEAF SPRING HOIST LIFT ARM WOODEN BLOCK Fig. 34 Spring Plate 1 - SPRING PLATE Fig. 32 Rear Shock Mounting Bolt 1 - SHOCK BOLT (4) Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove the weight of the axle from the rear springs. (5) Loosen and remove the spring plate bolts from the rear axle (Fig. 33). (6) Remove the spring plate from the rear axle and the leaf spring (Fig. 34). (7) Using the jack stands slowly lower the rear axle, permitting the rear springs to hang free. (8) Loosen and remove the 4 bolts securing the front mount of the leaf spring to the vehicle (Fig. 31). (9) Loosen and remove the nuts from the spring hanger (Fig. 35) for the rear leaf spring. Then remove the hanger plate from the hanger and remove the spring from the spring hanger (Fig. 35). (10) Remove the leaf spring from the vehicle. (11) Loosen and remove the pivot bolt from the front mount of the rear leaf spring. Remove mount. INSTALLATION - FWD (1) Assemble front spring mount to front of spring eye and install pivot bolt and nut. Do not tighten at this time. CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring. 2 - 42 REAR SUSPENSION RS SPRING - FWD (Continued) (8) Install spring plate bolts (Fig. 33). Tighten bolts to 95 N·m (70 ft. lbs.) torque. (9) Install lower shock absorber bolt. Do not tighten at this time. (10) Remove jack under axle. (11) Lower the vehicle and remove hoist arms and block of wood from under vehicle. Fig. 35 Rear Spring Hanger 1 - SHACKLE PLATE 2 - SPRING HANGER (2) Raise front of spring and install four mounting bolts (Fig. 31). Tighten bolts to 61 N·m (45 ft. lbs.) torque. (3) Install rear of spring onto rear spring shackle. Install shackle plate. Do not tighten. (4) Verify lower leaf spring isolator is in position. (5) Raise axle into correct position on leaf spring with axle centered under spring locator post (Fig. 36). CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque shown below. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the torque specification listed below. This sequence must be followed to properly seat the bushings into the springs and to avoid bending the spring hanger. (12) Tighten the spring front pivot bolt to 156 N·m (115 ft. lbs.) torque. (13) Tighten rear spring shackle pin nuts to 61 N·m (45 ft. lbs.) torque. (14) Tighten rear spring shackle inner to outer half retaining bolts to 61 N·m (45 ft. lbs.) torque. (15) Tighten the lower shock absorber mounting bolt to 102 N·m (75 ft. lbs.) torque. SPRING MOUNTS - FRONT REMOVAL (1) Raise vehicle on frame-contact hoist as follows: (a) Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown (Fig. 37). (b) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (c) Raise the vehicle to a comfortable working level. (2) Position an under-hoist utility jack or transmission jack under rear axle toward the side needing bushing replacement. Jack pad should just contact axle. (3) Remove shock absorber lower mounting bolt. Fig. 36 Leaf Spring Locator Post 1 - LEAF SPRING ISOLATOR 2 - LEAF SPRING 3 - LOCATOR POST (6) Verify that the leaf spring isolator is correctly positioned in the spring plate. (7) Install spring plate in position on the spring (Fig. 33). NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). (4) Remove four bolts securing leaf spring front mounting bracket to the body (Fig. 37). (5) Using jack, slowly lower rear axle, permitting the forward end of rear spring to hang down. Lower REAR SUSPENSION RS 2 - 43 SPRING MOUNTS - FRONT (Continued) shock absorber lower mounting bolt. Do not fully tighten bolt at this time. (5) Lower the vehicle and remove hoist arms and block of wood from under vehicle. (6) Tighten the spring front pivot bolt to 156 N·m (115 ft. lbs.) torque. (7) Tighten the lower shock absorber mounting bolt to 88 N·m (65 ft. lbs.) torque. SPRING MOUNTS - REAR REMOVAL (1) Remove the attaching nuts and bolts from the leaf spring rear shackle (Fig. 38) and (Fig. 39). Fig. 37 LIFTING POINT AND SPRING MOUNT 1 2 3 4 5 6 - BODY SILL AREA MOUNTING BOLTS SPRING MOUNTING BRACKET LEAF SPRING HOIST LIFT ARM WOODEN BLOCK it enough to allow access to spring pivot bolt. It may be necessary to place a wooden block between the spring and vehicle to hold forward end of the spring in place. (6) Remove leaf spring forward pivot bolt, then remove mounting bracket. Fig. 38 Leaf Spring Shackle Nuts (FWD) 1 - SHACKLE PLATE INSTALLATION (1) Position spring mounting bracket over spring eye and install pivot bolt through center of bushing from the outboard side. NOTE: The pivot bolt must be installed from the outboard side to allow proper bracket to body mounting. (2) Install the nut on the pivot bolt and lightly tighten. Do not fully tighten bolt at this time. (3) Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into place against the body. It may help to use a drift punch placed through the hole centered between the mounting bolt holes in the bracket and the pilot hole in the body of the vehicle as a guide. When the four mounting bolt holes line up with their threads in the body, Install the mounting bolts (Fig. 37). Tighten the four mounting bolts to 61 N·m (45 ft. lbs.) torque. (4) Raise or lower the jack until shock absorber lower eye aligns with threads in axle housing. Install Fig. 39 All-Wheel-Drive Rear Suspension 1 2 3 4 - SHACKLE - REAR MOUNT (HANGER) - LEAF SPRING (MULTI-LEAF) - AWD REAR AXLE 2 - 44 REAR SUSPENSION RS SPRING MOUNTS - REAR (Continued) (2) Install a jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand, support the weight of the axle and leaf spring. (3) Remove the lower mounting bolt from the shock absorber. (4) Remove the bolts attaching the leaf spring rear mount to the body of the vehicle (Fig. 40). The stabilizer bar interconnects both sides of the rear axle and attaches to the rear frame rails using 2 rubber isolated link arms. Both type stabilizer bars have the same basic components. Attachment to the rear axle tube, and rear frame rails is through rubber-isolated bushings. The 2 rubber isolated links are connected to the rear frame rails by brackets. These brackets are bolted to the bottom of the frame rails. OPERATION Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel to reduce body roll. REMOVAL REMOVAL - AWD Fig. 40 Rear Spring Mount 1 - LEAF SPRING MOUNT (5) Lower the jackstand and the rear of the leaf spring. Remove the shackle from the leaf spring bushing. INSTALLATION CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the specified torque. This sequence must be followed to avoid bending the spring hanger. (1) For installation, reverse removal procedure. Do not tighten rear spring shackle nuts fully until vehicle is lowered and the full vehicle weight is applied to the rear wheels. Tighten rear spring mount bolts to 61 N·m (45 ft. lbs.). Tighten shackle nuts to 61 N·m (45 ft. lbs.). STABILIZER BAR DESCRIPTION Front-wheel-drive models use a stabilizer bar that is mounted behind the rear axle. All-wheel-drive models use a stabilizer bar that is mounted in front of the rear axle. (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove the bolts securing the stabilizer bar to links on each end of the bar. (3) While holding the stabilizer bar in place, remove the bolts that attach the stabilizer bar bushing retainers to the rear axle. (4) Remove the stabilizer bar from the vehicle. (5) If the links need to be serviced, remove the upper link arm to bracket bolt. Then remove link arm from frame rail attaching bracket. REMOVAL - FWD (1) Raise vehicle. See Hoisting in Lubrication and Maintenance. (2) Remove the bolts securing the stabilizer bar to links on each side of bar. (3) While holding the stabilizer bar in place, remove the bolts that attach the stabilizer bar bushing retainers to the rear axle. (4) Remove the stabilizer bar from the vehicle. INSTALLATION INSTALLATION - AWD (1) Install the stabilizer bar on the rear axle. (2) Install bushing retainer bolts. Do not tighten at this time. (3) Install bolts connecting links to stabilizer bar. Do not tighten at this time. (4) Lower the vehicle so that the full weight of the vehicle is on all four tires. With the vehicle at its curb height, tighten the following bolts to the torques listed: • Stabilizer bar bushing retainer-to-axle bracket bolts — 61 N·m (45 ft. lbs.) REAR SUSPENSION RS 2 - 45 STABILIZER BAR (Continued) • Stabilizer bar-to-link bolts — 61 N·m (45 ft. lbs.) INSTALLATION - FWD (1) Lift the stabilizer bar onto the rear axle and install the two retainer mounting bolts. DO NOT TIGHTEN. (2) Install the bolts attaching the stabilizer bar links to the stabilizer bar. DO NOT TIGHTEN. (3) Lower the vehicle so that the full weight of the vehicle is on all four tires. With the vehicle at its curb height, tighten the following bolts to the torques listed: • Stabilizer bar bushing retainer-to-axle bracket bolts — 61 N·m (45 ft. lbs.) • Stabilizer bar-to-link — 61 N·m (45 ft. lbs.) (2) Remove the nut and bolt attaching the track bar to the track bar mount on the body of the vehicle. Remove the track bar from the track bar mount. INSTALLATION (1) Install the track bar first into the body mount for the track bar (Fig. 42). Install the track bar bolt with the head of the bolt facing toward the rear of the vehicle (Fig. 43). Do not tighten. TRACK BAR DESCRIPTION On front-wheel-drive applications of this vehicle that are equipped with single leaf rear springs, a track bar is used on the rear axle (Fig. 1). The track bar connects the rear axle to the frame/ body of the vehicle. The track bar is isolated from the body of the vehicle by an isolator bushing located in each end of the track bar. Fig. 42 Track Bar Installation (Typical) 1 - TRACK BAR REPLACEMENT OPERATION The track bar prevents excessive side-to-side movement of the rear axle. The track bar is used to keep the location of the axle in the correct position for optimum handling and control of the vehicle. REMOVAL (1) Remove the nut and bolt mounting the track bar to the rear axle (Fig. 41). Fig. 43 Track Bar Bolt Installation 1 - TRACK BAR BOLT Fig. 41 Track Bar Mounting To Axle (Typical) 1 - LOWER TRACK BAR BOLT INSTALLATION (2) Install the track bar into its mounting bracket on the rear axle (Fig. 41). Install the track bar bolt with the head of the bolt facing toward the rear of the vehicle. Do not tighten. (3) Lower the vehicle to the ground until the full weight of the vehicle is supported by the wheels. Tighten both track bar attaching bolts to a torque of 95 N·m (70 ft. lbs.). 2 - 46 WHEEL ALIGNMENT RS WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT DESCRIPTION - WHEEL ALIGNMENT . . . . . . . 46 DIAGNOSIS AND TESTING - SUSPENSION AND STEERING . . . . . . . . . . . . . . . . . . . . . . 49 STANDARD PROCEDURE STANDARD PROCEDURE - WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 51 STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . 54 STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT (EXPORT) . . . . . . . . . . . . . . 55 SPECIFICATIONS WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . 56 WHEEL ALIGNMENT • Excessive positive camber will cause tread wear on the outside of the tire. DESCRIPTION - WHEEL ALIGNMENT 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 camber bolt package and standard procedure) • Front 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 in this section for additional information. 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 (Fig. 1). 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. Fig. 1 Camber 1 - WHEELS TILTED OUT AT TOP 2 - WHEELS TILTED IN AT TOP WHEEL ALIGNMENT RS 2 - 47 WHEEL ALIGNMENT (Continued) CROSS CAMBER CROSS CASTER 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 +0.3° and the right camber is 0.0°, the cross camber would be +0.3°. Cross caster is the difference between left and right caster. 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 (Fig. 2). • 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. TOE Toe is the inward or outward angle of the wheels as viewed from above the vehicle (Fig. 3). • Toe-in is produced when the front edges of the wheels on the same axle are closer together than the rear edges. • Toe-out is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. 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 equally distant. Fig. 2 Caster Fig. 3 Toe 1 - TOE-IN 2 - TOE-OUT 2 - 48 WHEEL ALIGNMENT RS WHEEL ALIGNMENT (Continued) TOE-OUT ON TURNS STEERING AXIS INCLINATION (S. A. I.) Toe-out on turns is the relative positioning of the front wheels while steering through a turn (Fig. 4). 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. Steering axis inclination 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 (Fig. 5). 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. Fig. 5 S.A.I. and I.A. Fig. 4 Toe-Out On Turns 1 - TOE-OUT ON TURNS 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. 1 - S.A.I. 2 - CAMBER 3 - I.A. INCLUDED ANGLE (I. A.) Included angle is the sum of the S.A.I. angle plus or minus the camber angle, depending on whether or not the wheel has positive or negative camber (Fig. 5). 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). WHEEL ALIGNMENT RS 2 - 49 WHEEL ALIGNMENT (Continued) THRUST ANGLE Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle’s center line (Fig. 6). 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. Fig. 6 Thrust Angle DIAGNOSIS AND TESTING - SUSPENSION AND STEERING CONDITION Front End Whine On Turns Front End Growl Or Grinding On Turns Front End Clunk Or Snap On Turns POSSIBLE CAUSES 1. Defective wheel bearing CORRECTION 1. Replace wheel bearing 2. Incorrect wheel alignment 2. Check and reset wheel alignment 3. Worn tires 3. Replace tires 1. Defective wheel bearing 1. Replace wheel bearing 2. Engine mount grounding 2. Check for motor mount hitting frame rail and reposition engine as required 3. Worn or broken C/V joint 3. Replace C/V joint 4. Loose wheel lug nuts 4. Verify wheel lug nut torque 5. Incorrect wheel alignment 5. Check and reset wheel alignment 6. Worn tires 6. Replace tires 7. Front strut pin in upper strut mount 7. Replace the front strut upper mount and bearing 1. Loose lug nuts 1. Verify wheel lug nut torque 2. Worn or broken C/V joint 2. Replace C/V joint 3. Worn or loose tie rod 3. Tighten or replace tie rod end 4. Worn or loose ball joint 4. Tighten or replace ball joint 5. Worn/loose control arm bushing 5. Replace control arm bushing 6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified torque 2 - 50 WHEEL ALIGNMENT RS WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION 7. Loose strut mount to body attachment 7. Tighten strut attachment to specified torque 8. Loose crossmember bolts 8. Tighten crossmember bolts to specified torque 1. Defective wheel bearing 1. Replace wheel bearing 2. Incorrect wheel alignment 2. Check and reset wheel alignment 3. Worn tires 3. Replace tires 4. Worn or defective transaxle gears or bearings 4. Replace transaxle gears or bearings 1. Engine mount grounding 1. Reposition engine as required 2. Worn or broken C/V joint 2. Replace C/V joint Front End Whine When Accelerating Or Decelerating 1. Worn or defective transaxle gears or bearings 1. Replace transaxle gears or bearings Front End Clunk When Accelerating Or Decelerating 1. Worn or broken engine mount 1. Replace engine mount 2. Worn or defective transaxle gears or bearings 2. Replace transaxle gears or bearings 3. Loose lug nuts 3. Verify wheel lug nut torque 4. Worn or broken C/V joint 4. Replace C/V joint 5. Worn or loose ball joint 5. Tighten or replace ball joint 6. Worn or loose control arm bushing 6. Replace control arm bushing 7. Loose crossmember bolts 7. Tighten crossmember bolts to specified torque 8. Worn tie rod end 8. Replace tie rod end 1. Incorrect tire pressure 1. Inflate tires to recommended pressure Front End Whine With Vehicle Going Straight At A Constant Speed Front End Growl Or Grinding With Vehicle Going Straight At A Constant Speed Road Wander Lateral Pull 2. Incorrect front or rear wheel toe 2. Check and reset wheel toe 3. Worn wheel bearings 3. Replace wheel bearing 4. Worn control arm bushings 4. Replace control arm bushing 5. Excessive friction in steering gear 5. Replace steering gear 6. Excessive friction in steering shaft coupling 6. Replace steering coupler 7. Excessive friction in strut upper bearing 7. Replace strut bearing 1. Unequal tire pressure 1. Inflate all tires to recommended pressure 2. Radial tire lead 2. Perform lead correction procedure WHEEL ALIGNMENT RS 2 - 51 WHEEL ALIGNMENT (Continued) CONDITION Excessive Steering Free Play Excessive Steering Effort POSSIBLE CAUSES CORRECTION 3. Incorrect front wheel camber 3. Check and reset front wheel camber 4. Power steering gear imbalance 4. Replace power steering gear 5. Wheel braking 5. Correct braking condition causing lateral pull 1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear 2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends 3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to specified torque 4. Loose or worn steering shaft coupler 4. Replace steering shaft coupler 1. Low tire pressure 1. Inflate all tires to recommended pressure 2. Lack of lubricant in steering gear 2. Replace steering gear 3. Low power steering fluid level 3. Fill power steering fluid reservoir to correct level 4. Loose power steering pump drive belt 4. Correctly adjust power steering pump drive belt 5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints 6. Steering gear malfunction 6. Replace steering gear 7. Lack of lubricant in steering coupler 7. Replace steering coupler STANDARD PROCEDURE STANDARD PROCEDURE - 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 ensure proper alignment. (1) Verify that the fuel tank is full of fuel. If the tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment angles. (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. All tires must be the same size and in good condition with approximately the same amount of tread wear. Inflate all the tires to the recommended air pressure. (4) Check the front wheel and tire assemblies for excessive radial runout. (5) Inspect lower ball joints and all steering linkage for looseness, binding, wear or damage. Repair as necessary. (6) Check suspension fasteners for proper torque and retighten as necessary. (7) Inspect all suspension component rubber bushings for signs of wear or deterioration. Replace any faulty bushings or components before aligning the vehicle. (8) Check the vehicle’s curb height to verify it is within specifications. Refer to Curb Height Measurement. 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 align- 2 - 52 WHEEL ALIGNMENT RS WHEEL ALIGNMENT (Continued) ment settings to the vehicle specifications for camber, caster and toe-in. (Refer to 2 - SUSPENSION/ WHEEL ALIGNMENT - SPECIFICATIONS) (4) If front camber and caster are not within specifications, proceed to CAMBER AND CASTER below. If caster and camber are within specifications, proceed to TOE which can be found following CAMBER AND CASTER. Rear camber, caster and toe are not adjustable. If found not to be within specifications, reinspect for damaged suspension or body components and replace as necessary. CAMBER AND CASTER 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. Camber and caster should be checked to ensure they meet vehicle specifications. If front camber is found not to meet alignment specifications, it can be adjusted using an available camber adjustment bolt package. Before installing a camber adjustment bolt package on a vehicle found to be outside the specifications, inspect the suspension components for any signs of damage or bending. CAUTION: Do not attempt to adjust the vehicles wheel alignment by heating, bending or by performing any other modification to the vehicle’s front suspension components or body. If camber readings are not within specifications, use the following procedure to install the front camber adjustment bolt package and then adjust front camber. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION The camber adjustment bolt package contains 2 flange bolts, 2 cam bolts, 2 dog bone washers, and 4 nuts. This package services both sides of the vehicle. Use the package to attach the strut clevis bracket to the steering knuckle after the strut clevis bracket has been modified. To install and adjust the camber adjustment bolt package, follow the procedure below. (1) Raise the vehicle until its tires are not supporting the weight of the vehicle. (2) Remove the front tire and wheel assemblies. CAUTION: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to support the steering knuckle assembly or if required remove the brake flex hose from the caliper assembly. CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary. (3) Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts (Fig. 7)and discard. Separate the steering knuckle from the strut clevis bracket and position steering knuckle so it is out of the way of the strut. Fig. 7 Clevis Bracket To Steering Knuckle Attaching Bolts 1 2 3 4 5 - STRUT CLEVIS BRACKET - ATTACHING BOLTS - TIE ROD END - ROTOR - STEERING KNUCKLE CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the hole beyond the indentations on the sides of the strut clevis bracket (Fig. 8). (4) Using an appropriate grinder and grinding wheel, slot the bottom hole in both sides of the strut clevis bracket (Fig. 8). CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog bone washers from the service package must be used to attach the steering knuckle to the strut after the mounting hole is slotted. WHEEL ALIGNMENT RS 2 - 53 WHEEL ALIGNMENT (Continued) (6) Install a dog bone washer on the steering knuckle to strut clevis bracket attaching bolts, then install the nuts onto the bolts from the service package (Fig. 10). Tighten the bolts just enough to hold the steering knuckle in position when adjusting camber, while still allowing the steering knuckle to move in clevis bracket. Fig. 8 Strut Clevis Bracket Bolt Hole Grinding Area 1 - UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE 2 - CAMBER ADJUSTMENT SLOT INDENTATION AREA ON CLEVIS BRACKET 3 - LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE 4 - STRUT CLEVIS BRACKET NOTE: The strut clevis-to-knuckle bolts are installed differently on each side of the vehicle. Left-handside bolts are installed from vehicle rear to front (Fig. 9). Right-hand-side bolts are installed from vehicle front to rear. (5) Position the knuckle back into the strut clevis bracket. Using the direction indicated in the above note, install a flanged bolt from the service package into the upper mounting hole. Using the direction indicated in the above note, install a cam bolt into the bottom mounting hole (Fig. 9). Fig. 9 Package Bolts Correctly Installed 1 2 3 4 - STEERING KNUCKLE FLANGED BOLT IN TOP HOLE CAM BOLT IN BOTTOM HOLE STRUT CLEVIS BRACKET Fig. 10 Dog Bone Washer And Nuts Installed 1 2 3 4 - STEERING KNUCKLE - DOG BONE WASHER - STRUT CLEVIS BRACKET - ATTACHING NUTS (7) Repeat the procedure to the other side strut clevis bracket. (8) Reinstall both front tire and wheel assemblies and tighten to specifications. (9) Lower the vehicle. Jounce the front and rear of vehicle an equal amount of times. (10) Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against the cam stop areas on the strut clevis bracket (Fig. 11). When camber is set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again jounce front and rear of vehicle an equal amount of times and verify front camber setting. Torque both front strut to steering knuckle attaching bolts to 81 N·m (60 ft. lbs.) plus an additional 1/4 (90°) turn after the required torque is met. (11) If toe readings obtained are not within the required specification range, adjust toe to meet the preferred specification setting. Toe is adjustable using the following procedure. TOE (1) Center the steering wheel and lock in place using a steering wheel clamp. 2 - 54 WHEEL ALIGNMENT RS WHEEL ALIGNMENT (Continued) Fig. 12 Front Wheel Toe Adjustment Fig. 11 Camber Adjustment Cam Bolt 1 - STEERING KNUCKLE 2 - CLEVIS BRACKET CAM STOP AREAS 3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. (2) Loosen front inner to outer tie rod end jam nuts (Fig. 12). Grasp inner tie rods at serrations and rotate inner tie rods of steering gear (Fig. 12) to set front toe to the preferred toe specification. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - SPECIFICATIONS) (3) Tighten tie rod jam nuts (Fig. 12) to 75 N·m (55 ft. lbs.) torque. (4) Adjust steering gear to tie rod boots at the inner tie rod. (5) Remove steering wheel clamp. (6) Remove the alignment equipment. (7) Road test the vehicle to verify the steering wheel is straight and the vehicle does not wander or pull. STANDARD PROCEDURE - 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 1 2 3 4 5 - INNER TIE ROD SERRATION OUTER TIE ROD JAM NUT OUTER TIE ROD END INNER TIE ROD STEERING KNUCKLE 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. (1) Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. (2) When measuring, the maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). (3) Compare the measurements to the specifications listed in the following Curb Height Specifications charts. WHEEL ALIGNMENT RS 2 - 55 WHEEL ALIGNMENT (Continued) CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES TIRE SALES CODE/TIRE SIZE FRONT REAR TM4 / 215/70 R 15 754 mm ± 10 mm 29.68 in. ± 0.39 in. 770 mm ± 10 mm 30.31 in. ± 0.39 in. TM5 / 215/65 R 16 755 mm ± 10 mm 29.72 in. ± 0.39 in. 771 mm ± 10 mm 30.35 in. ± 0.39 in. TTU / 215/60 R 17 758 mm ± 10 mm 29.84 in. ± 0.39 in. 774 mm ± 10 mm 30.47 in. ± 0.39 in. CURB HEIGHT SPECIFICATIONS - SHORT WHEEL BASE VEHICLES TIRE SALES CODE/TIRE SIZE FRONT REAR TM4 / 215/70 R 15 755 mm ± 10 mm 29.72 in. ± 0.39 in. 770 mm ± 10 mm 30.31 in. ± 0.39 in. TM5 / 215/65 R 16 756 mm ± 10 mm 29.76 in. ± 0.39 in. 771 mm ± 10 mm 30.35 in. ± 0.39 in. STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT (EXPORT) 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. (1) Measure from the inboard edge of the wheel opening fender lip directly above the wheel center (spindle), to the floor or alignment rack surface. (2) When measuring, the maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). (3) Compare the measurements to the specifications listed in the following Curb Height Specifications charts. CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES WITH SDF SUSPENSION TIRE SALES CODE/TIRE SIZE FRONT REAR TMM / 215/65 R 16 756 mm ± 10 mm 29.76 in. ± 0.39 in. 772 mm ± 10 mm 30.39 in. ± 0.39 in. CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES WITH SDF + SER SUSPENSION TIRE SALES CODE/TIRE SIZE FRONT REAR TMM / 215/65 R 16 756 mm ± 10 mm 29.76 in. ± 0.39 in. 771 mm ± 10 mm 30.35 in. ± 0.39 in. CURB HEIGHT SPECIFICATIONS - SHORT WHEEL BASE VEHICLES TIRE SALES CODE/TIRE SIZE FRONT REAR TMM / 215/65 R 16 755 mm ± 10 mm 29.72 in. ± 0.39 in. 770 mm ± 10 mm 30.31 in. ± 0.39 in. 2 - 56 WHEEL ALIGNMENT RS WHEEL ALIGNMENT (Continued) SPECIFICATIONS WHEEL ALIGNMENT NOTE: All specifications are given in degrees. NOTE: All wheel alignments are to be set at curb height. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE) FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE +0.10° -0.30° to +0.50° 0.0° 0.50° +2.31° +1.31° to +3.31° 0.0° 1.00° +0.10° 20.10° to +0.30° 0.0° 0.06° PREFERRED SETTING ACCEPTABLE RANGE CAMBER* 0.0° -0.25° to +0.25° TOTAL TOE* ** 0.0° 20.20° to +0.20° THRUST ANGLE* 0.0° -0.30° to +0.30° CAMBER Cross-Camber (Maximum side-to-side difference) CASTER* Cross-Caster (Maximum side-to-side difference) TOTAL TOE** Maximum side-to-side difference REAR WHEEL ALIGNMENT Notes: * For reference only. These are non-adjustable angles. ** TOTAL TOE is the sum of both left and right wheel toe settings. TOTAL TOE must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe is toe-out RESTRAINTS RS 8O - 1 RESTRAINTS TABLE OF CONTENTS page RESTRAINTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING ........................... DIAGNOSIS AND TESTING - AIRBAG SYSTEM CLOCK SPRING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - CLOCK SPRING CENTERING . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL ........................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . DRIVER AIRBAG DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - CLEAN UP . . . . . REMOVAL ........................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . DRIVER AIRBAG TRIM COVER REMOVAL ........................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . OCCUPANT RESTRAINT CONTROLLER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL ........................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . PASSENGER AIRBAG DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - CLEAN UP . . . . . REMOVAL ........................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . SEAT AIRBAG DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT BELT OUTBOARD FRONT REMOVAL ........................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . SEAT BELT FIRST ROW ANCHOR BRACKET LWB REMOVAL ........................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . SEAT BELT LEFT FIRST ROW OUTBOARD SWB THREE DOOR REMOVAL ........................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . ..2 ..2 ..2 .2 ..3 ..3 ..3 ..3 ..3 . . . . . .3 .3 .4 .4 .4 ..4 ..5 . . . . .5 .5 .5 .5 . . . . . .6 .6 .6 .6 .6 ..7 ..7 ..7 ..7 ..8 ..8 ..8 ..8 page SEAT BELT FIRST ROW OUTBOARD - SWB FOUR DOOR REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SEAT BELT FIRST ROW OUTBOARD - LWB FOUR DOOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 SEAT BELT SECOND RIGHT ROW OUTBOARD - LWB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 SEAT BELT SECOND RIGHT ROW OUTBOARD - LBW WITH REAR HVAC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 SEAT BELT SECOND ROW OUTBOARD - SWB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 SEAT BELT BUCKLE - FRONT INBOARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 SEAT BELT BUCKLE FIRST ROW QUAD BUCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 SEAT BELT BUCKLE FIRST ROW - TWO PASSENGER BENCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 SEAT BELT BUCKLE SECOND ROW - THREE PASSENGER BENCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 SEAT BELT TENSIONER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SHOULDER BELT HEIGHT ADJUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 SHOULDER BELT HEIGHT ADJUSTER KNOB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 SIDE IMPACT AIRBAG CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 8O - 2 RESTRAINTS RESTRAINTS DESCRIPTION This vehicle is equipped with a Frontal Impact Airbag System, which utilizes the driver/passenger airbags and seatbelt pretensioners. This system is designed to protect occupants in the event of a front impact collision. These airbags and seatbelt pretensioners are all serviceable parts. If these pyrotechnics are deployed or defective, they must be replaced, as well as the Occupant Restraint Controller (ORC) must be diagnosed following procedures outlined in the service/diagnostic manuals. Vehicles equipped with the Side Impact Airbag System, the seat back assembly must be replaced, as well as the Side Impact Airbag Control Module (SIACM) must be diagnosed following procedures outlined in the service/diagnostic manuals. OPERATION The Occupant Restraint Controller (ORC) controls the driver/passenger airbags and seatbelt pretensioners. If the ORC determines the impact is severe enough, the driver/passenger airbags and seatbelt pretensioners will inflate. Once a deployment occurs, these devices, and all damaged parts must be replaced, as well as the ORC must be diagnosed following procedures outlined in the service/diagnostic manuals. The Side Impact Airbag Control Module (SIACM), the seat back assemblies and all damaged parts must be replaced, as well as the SIACM must be diagnosed following procedures outlined in the service/diagnostic manuals. WARNING WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX ELECTRO–MECHANICAL UNIT. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE DOWN ON A SOLID SURFACE, THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN PERSONAL INJURY. WHEN CARRYING OR HANDLING AN UNDEPLOYED AIRBAG MODULE, THE TRIM SIDE OF THE AIRBAG SHOULD BE POINTING AWAY RS FROM THE BODY TO MINIMIZE POSSIBILITY OF INJURY IF ACCIDENTAL DEPLOYMENT OCCURS. REPLACE AIRBAG SYSTEM COMPONENTS WITH MOPART REPLACEMENT PARTS. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. WEAR SAFETY GLASSES, RUBBER GLOVES, AND LONG SLEEVED CLOTHING WHEN CLEANING POWDER RESIDUE FROM VEHICLE AFTER AIRBAG DEPLOYMENT. SODIUM HYDROXIDE POWDER RESIDUE EMITTED FROM A DEPLOYED AIRBAG CAN CAUSE SKIN IRRITATION. FLUSH AFFECTED AREA WITH COOL WATER IF IRRITATION IS EXPERIENCED. IF NASAL OR THROAT IRRITATION IS EXPERIENCED, EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF IRRITATION CONTINUES, SEE A PHYSICIAN. DO NOT USE A REPLACEMENT AIRBAG THAT IS NOT IN THE ORIGINAL PACKAGING, IMPROPER DEPLOYMENT AND PERSONAL INJURY CAN RESULT. THE FACTORY INSTALLED FASTENERS, SCREWS AND BOLTS USED TO FASTEN AIRBAG COMPONENTS HAVE A SPECIAL COATING AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. DO NOT USE SUBSTITUTE FASTENERS, USE ONLY ORIGINAL EQUIPMENT FASTENERS LISTED IN THE PARTS CATALOG WHEN FASTENER REPLACEMENT IS REQUIRED. CAUTION: Deployed and Nondeployed Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. DIAGNOSIS AND TESTING - AIRBAG SYSTEM (1) Connect a DRB lllt scan tool to the Data Link Connector (DLC), located at left side of the steering column and at the lower edge of the lower instrument panel. (2) Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. (3) After checking that no one is inside the vehicle, connect the battery negative terminal. (4) Using the DRB lllt scan tool, read and record active diagnostic code data. (5) Read and record any stored diagnostic codes. RESTRAINTS RS 8O - 3 RESTRAINTS (Continued) (6) Refer to the proper Body Diagnostic Procedures manual if any diagnostic codes are found in Step 4 or Step 5. (7) Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper Body Diagnostic Procedures Manual to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose the problem. CLOCK SPRING DESCRIPTION The clock spring is screwed to a plastic mounting platform on the steering column behind the steering wheel. The clock spring is used to maintain a continuous electrical circuit between the wiring harness and the drivers airbag. OPERATION This assembly consists of a flat ribbon like electrically conductive tape which winds and unwinds with the steering wheel rotation. The clock spring cannot be repaired. If the clock spring is faulty, damaged, or if the airbag has been deployed, the clock spring must be replaced. STANDARD PROCEDURE - CLOCK SPRING CENTERING If the rotating tape (wire coil) in the clock spring is not positioned properly with the steering wheel and the front wheels, the clock spring may fail. The following procedure MUST BE USED to center the clock spring if it is not known to be properly positioned, or if the front wheels were moved from the straight ahead position. (1) Adjust the steering wheel so that the tires are in a straight ahead position. (2) Remove Driver Airbag from steering wheel. (3) Disconnect wire connectors from back of airbag. (4) Remove steering wheel. (5) Rotate the clock spring rotor clockwise until the rotor stops. Do not apply excessive force. (6) From the end of travel, rotate the rotor two turns counterclockwise until the wires end up at the top. (7) Install steering wheel and airbag. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. REMOVAL (1) Position steering wheel and front wheels straight ahead. (2) Release hood latch and open hood. Disconnect and isolate the battery negative cable. (3) Remove driver airbag from steering wheel. (4) Disconnect wire connectors from back of driver airbag. (5) Disconnect the 2–way connector from remote radio control harness and the 4-way connector from the speed control/horn harness. (6) Remove steering wheel. (7) Remove steering column shrouds. (8) Disconnect 4-way and 6-way connectors between the clock spring and the instrument panel wiring harness. (9) Remove clock spring from housing assembly by removing the two retaining screws retaining the clock spring. INSTALLATION (1) Position the clock spring into the housing. Install the two retaining screws to clock spring. (2) Connect the 4-way and 6-way harness between the clock spring and the instrument panel. (3) Install the steering wheel. Refer to Steering, Column, Steering Wheel, Installation. (4) Connect the harness connector to the driver airbag. (5) Connect the remote radio control harness and the speed control/horn harness. (6) Install the driver airbag into the steering wheel. (7) Install the steering column upper and lower shrouds. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. DRIVER AIRBAG DESCRIPTION The Driver Airbag is located in the center of the steering wheel. The most visible part of the airbag is the cover/horn switch. OPERATION The Driver Airbag cover contains the horn switch, inflator device, and a fabric bag. The airbag cover/ horn switch is serviced separately from the inflator and bag components. 8O - 4 RESTRAINTS RS DRIVER AIRBAG (Continued) When the front airbag system is deployed, the following MUST be replaced: • Complete Steering Column Assembly. • Lower Steering Column Coupler. • Steering Wheel. • Clock Spring. • Driver Airbag • Passenger Airbag • Upper Instrument Panel with Pad. CARE OF UNDEPLOYED AIRBAGS Airbags must be stored in their original special container until used for service. At no time should a source of electricity be permitted near the inflator on the back of an airbag. When carrying or handling an undeployed airbag, the trim side of the airbag should be pointing away from the body to minimize possibility of injury if accidental deployment occurs. Do not place undeployed airbag face down on a solid surface, the airbag will propel into the air if accidental deployment occurs. STANDARD PROCEDURE - CLEAN UP Roll or fold the driver airbag towards the steering wheel and then tape the bag to the steering wheel. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Work from the outside in to avoid kneeling or sitting in a contaminated area. Vacuum the heater and A/C outlets as well. If HVAC was in RECIRC mode at time of airbag deployment, operate HVAC blower on low speed/heat and vacuum powder residue expelled from the heat outlets. Multiple vacuum cleaning may be necessary to decontaminate the interior of the vehicle. REMOVAL DEPLOYED AIRBAG The Driver Airbag and Driver Airbag Cover/Horn Pad are serviced separately from each other. (1) Clean powder residue from interior of vehicle, (Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - STANDARD PROCEDURE ) Cleanup. (2) Remove two screws attaching Driver Airbag to steering wheel. (3) Remove the driver airbag from steering wheel. (4) Disconnect wire connectors from Airbag and Clock Spring. (5) Adjust the steering wheel so that the tires are in a straight ahead position. Remove steering wheel, (Refer to 19 - STEERING/COLUMN/STEERING WHEEL - REMOVAL) (6) Disconnect the 2-way and 4-way connectors between the clock spring and the instrument panel wiring harness. (7) Remove upper and lower steering column shrouds. (8) Remove clock spring from the housing assembly by depressing the 2 tabs on the clock spring. UNDEPLOYED AIRBAG (1) Remove screws attaching airbag/horn switch to steering wheel. (2) Remove Driver Airbag from steering wheel. (3) Disconnect wire connectors from driver airbag and clock spring. INSTALLATION DEPLOYED AIRBAG (1) Perform cleanup procedure.(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - STANDARD PROCEDURE) (2) Install a new steering column assembly and lower steering column coupler. Refer to Steering, Column, Installation. (3) Install the clock spring. (4) Install the driver airbag and the two screws retaining the airbag. Tighten screws to 10 N·m (90 in. lbs.) WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. UNDEPLOYED AIRBAG (1) Position a new airbag into the airbag cavity. (2) Install the two screws retaining the airbag. Tighten screws to 10 N·m (90 in. lbs.) WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. DRIVER AIRBAG TRIM COVER REMOVAL The horn switch is integral to the driver airbag trim cover. If either component is faulty or damaged, the entire driver airbag trim cover and horn switch unit must be replaced. (1) Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE. RESTRAINTS RS 8O - 5 DRIVER AIRBAG TRIM COVER (Continued) just forward of the storage bin. The ORC monitors the system to determine the system readiness. The ORC contains on-board diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs. (2) Remove the driver airbag from the steering wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/ DRIVER AIRBAG - REMOVAL). (3) Remove the plastic wire retainer that captures the horn switch feed pigtail wire between the upper left inflator stud and the inflator on the back of the driver airbag housing. (4) Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the back of the driver airbag housing. (5) Remove the upper and lower trim cover retainers from the airbag housing studs. (6) Remove the horn switch ground pigtail wire eyelet terminal from the upper right airbag housing stud. (7) Disengage the six trim cover locking blocks from the lip around the outside edge of the driver airbag housing and remove the housing from the cover. The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Occupant Restraint Controller (ORC). The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ORC microprocessor sends a signal that completes the electrical circuit to the driver and passenger airbags. The impact sensor is calibrated for the specific vehicle and reacts to the severity and direction of an impact. INSTALLATION REMOVAL (1) Install the housing into the cover. Engage the six trim cover locking blocks to the lip around the outside edge of the driver airbag housing. (2) Install the horn switch ground pigtail wire eyelet terminal to the upper right airbag housing stud. (3) Install the upper and lower trim cover retainers to the airbag housing studs. (4) Install the four nuts that secure the upper and lower trim cover retainers to the studs on the back of the driver airbag housing. (5) Install the plastic wire retainer that captures the horn switch feed pigtail wire between the upper left inflator stud and the inflator on the back of the driver airbag housing. (6) Install the driver airbag onto the steering wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/ DRIVER AIRBAG - INSTALLATION). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. FIRST (Refer to 8 - ELECTRICAL/RESTRAINTS/DIAGNOSIS AND TESTING - AIRBAG SYSTEM). OCCUPANT RESTRAINT CONTROLLER DESCRIPTION The front driver and passenger airbag system is designed to reduce the risk of fatality or serious injury, caused by a frontal impact of the vehicle. The Occupant Restraint Controller (ORC) contains the impact sensor and energy reserve capacitor. It is mounted on a bracket, under the instrument panel, OPERATION NOTE: Diagnose the ORC using the service/diagnostic manual. (1) Disconnect and isolate the battery negative cable. (2) Remove storage bin from instrument panel. Refer to Body, Instrument Panel, Storage Bin, Removal. (3) Remove three bolts holding ORC to floor bracket. (4) Disconnect the wire connector from ORC. (5) Remove the ORC assembly from vehicle. INSTALLATION WARNING: DO NOT INSTALL ORC IF MOUNTING LOCATION IS DEFORMED OR DAMAGED. CAUTION: Use correct screws when installing the ORC. (1) Install the ORC assembly into vehicle. (2) Connect the wire connector to the ORC. (3) Install three bolts holding ORC to floor bracket. Torque bolts to 7.3 - 9.6 N·m (65 to 85 in. lbs.) (4) Install the storage bin onto the instrument panel. Refer to Body, Instrument Panel, Storage Bin, Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. 8O - 6 RESTRAINTS PASSENGER AIRBAG DESCRIPTION WARNING: NEVER DISASSEMBLE THE PASSENGER AIRBAG, THE PASSENGER AIRBAG HAS NO SERVICEABLE PARTS. The Passenger Airbag is located beneath the instrument panel and pad assembly. The airbag is mounted to the back side of the instrument panel reinforcement. The instrument panel top pad is the most visible part of the passenger airbag system. Located under the instrument panel top pad are the airbag door, the passenger airbag cushion and the airbag cushion supporting components. The passenger airbag includes a magnesium housing within which the cushion and inflator are mounted and sealed. Following a passenger airbag deployment, the passenger airbag and the instrument panel must be replaced. The passenger airbag cannot be repaired, and must be replaced if deployed or damaged in any way. OPERATION The passenger airbag is equipped with two inflators, each with three levels of pressure output. The inflators seal the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. Following an airbag deployment, the airbag cushion quickly deflates by venting this gas through the cushion material towards the instrument panel. The passenger airbag is secured with screws to the instrument panel beneath the instrument panel top pad and above the glove box opening. The instrument panel top pad above the glove box opening conceals the airbag door and a predetermined hinge line beneath its decorative cover. Upon airbag deployment, the top pad will bend at the hinge line and the door will fold back out of the way onto the top of the instrument panel. When the front airbag system is deployed, the following MUST be replaced: • Complete Steering Column Assembly. • Lower Steering Column Coupler. • Steering Wheel. • Clock Spring. • Driver Airbag. • Passenger Airbag. • Upper Instrument Panel with Pad. RS CARE OF UNDEPLOYED AIRBAGS Airbags must be stored in their original special container until used for service. At no time should a source of electricity be permitted near the inflator on the back of an airbag. When carrying or handling an undeployed airbag, the trim side of the airbag should be pointing away from the body to minimize possibility of injury if accidental deployment occurs. Do not place undeployed airbag face down on a solid surface, the airbag will propel into the air if accidental deployment occurs. STANDARD PROCEDURE - CLEAN UP Roll or fold the passenger airbag towards the instrument panel surface and close the door over the folded bag. Then tape the door shut. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Work from the outside in to avoid kneeling or sitting in a contaminated area. Vacuum the heater and A/C outlets as well. If HVAC was in RECIRC mode at time of airbag deployment, operate HVAC blower on low speed/heat and vacuum powder residue expelled from the heat outlets. Multiple vacuum cleaning may be necessary to decontaminate the interior of the vehicle. REMOVAL DEPLOYED AIRBAG (1) Clean powder residue from interior of vehicle. Refer to Electrical, Restraints, Passenger Airbag, Standard Procedure - Passenger Airbag Clean Up. (2) Remove instrument panel. Refer to Body, Instrument Panel, Removal. (3) Remove all reusable components from the upper instrument panel and transfer to the new instrument panel. UNDEPLOYED AIRBAG (1) Remove instrument panel. Refer to Body, Instrument Panel, Removal. (2) De-trim the instrument panel enough to gain access to the passenger airbag fasteners. (3) Disconnect yellow wire connector from passenger airbag. (4) Remove three bolts to the passenger airbag. (5) Remove airbag from instrument panel through rear of instrument panel. INSTALLATION DEPLOYED AIRBAG Transfer all reusable components to the new instrument panel. (1) Install new Passenger Airbag into instrument panel. RESTRAINTS RS 8O - 7 PASSENGER AIRBAG (Continued) (2) Install airbag attaching bolts to the instrument panel. (3) Connect yellow wire connector from passenger airbag. (4) Install Instrument panel. Refer to Body, Instrument Panel, Installation. One in each front seat. The seat airbag inflator assembly is within the airbag housing (Fig. 1). Each airbag is mounted to the seat back frame. If deployed or defective, the entire seat back assembly must be replaced. OPERATION WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. UNDEPLOYED AIRBAG (1) Install Passenger Airbag into instrument panel. (2) Install airbag attaching bolts to the instrument panel. (3) Connect yellow wire connector from passenger airbag. (4) Install Instrument panel. Refer to Body, Instrument Panel, Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. SEAT AIRBAG DESCRIPTION Only the Side Impact Airbag Control Module (SIACM) can deploy the side airbags. When supplied with the proper electrical signal, the seat airbag inflator will produce a gas and discharge the bag directly between the occupant and the side of the vehicle, protecting the occupant. Upon deployment, the seat back trim cover will tear open and allow the side airbag to fully inflate and quickly deflate. SEAT BELT OUTBOARD FRONT REMOVAL Inspect the condition of the shoulder belt and lap belt. Replace any belt that is cut, frayed, torn, or damaged in any way. Also, replace the shoulder belt if the retractor is either damaged or inoperative. (1) Remove shoulder harness height adjuster knob by pulling it straight away from adjuster. (2) Remove cover from seat belt turning loop. (3) Remove bolt attaching turning loop to shoulder belt height adjuster (Fig. 2). (4) Remove turning loop from B-pillar. (5) Remove lower B-pillar trim cover or quarter trim panel. (6) Remove bolt attaching seat belt retractor to B-pillar (Fig. 2). (7) Lift retractor upward and disengage arrow head retainer attaching retractor to B-pillar. (8) Remove seat belt from vehicle. INSTALLATION Fig. 1 SEAT AIRBAG - TYPICAL The side impact airbag system Seat Airbags are located in the outboard side of the front seat backs. Inspect the condition of the shoulder belt and lap belt. Replace any belt that is cut, frayed, torn, or damaged in any way. Also, replace the shoulder belt if the retractor is either damaged or inoperative. (1) Place seat belt into position. (2) Lower retractor into position B-pillar. (3) Install bolt attaching seat belt retractor to B-pillar. Tighten all seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (4) Install turning loop onto B-pillar. (5) Install lower B-pillar trim cover or quarter trim panel. (6) Install bolt attaching turning loop to shoulder belt height adjuster. Tighten all seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (7) Press cover onto the seat belt turning loop. 8O - 8 RESTRAINTS RS SEAT BELT OUTBOARD FRONT (Continued) SEAT BELT LEFT FIRST ROW OUTBOARD - SWB THREE DOOR REMOVAL Fig. 2 SEAT BELT - OUTBOARD FRONT 1 - B-PILLAR TRIM LOWER 2 - BELT 3 - B-PILLAR TRIM UPPER 4 - HEIGHT ADJUSTER 5 - KNOB 6 - B-PILLAR TRIM LOWER 7 - FLOOR ANCHOR 8 - FLOOR ANCHOR 9 - 30° OUTBOARD 10 - RETRACTOR (8) Install shoulder harness height adjuster knob by pushing onto the adjuster. SEAT BELT FIRST ROW ANCHOR BRACKET - LWB REMOVAL (1) Remove lower quarter trim panel. (2) Remove bolt attaching first row seat belt anchor bracket to floor. (3) Remove bracket from vehicle. INSTALLATION (1) Position bracket to vehicle. (2) Install bolt attaching first row seat belt anchor bracket to floor. (3) Install lower quarter trim panel. NOTE: The tightening specification for all seat belt anchor bolts is 39 N·m (29 ft. lbs.) torque. (1) Remove first and second row seats. Refer to Owner’s manual for proper procedures. (2) Remove shoulder harness height adjuster knob by pulling it straight away from adjuster. (3) Slide floor anchor cover from over the anchor bolt. (4) Remove floor anchor bolt (Fig. 3). (5) Remove anchor from floor. (6) Open clam shell cover from over seat belt turning loop. (7) Remove bolt attaching turning loop to shoulder belt height adjuster. (8) Remove turning loop from C-pillar. (9) Remove B-pillar upper trim cover. (10) Remove C-pillar upper trim cover. (11) Remove lower quarter trim panel. (12) Route seat belt webbing and turning loop through access hole in lower quarter trim panel. (13) Remove bolt attaching seat belt retractor to quarter panel. (14) Lift retractor upward and disengage arrow head retainer attaching retractor to quarter panel (Fig. 3). (15) Remove seat belt from vehicle. INSTALLATION (1) Install seat belt into position. (2) Lower retractor into position to quarter panel. (3) Install bolt attaching seat belt retractor to quarter panel. Tighten all seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (4) Install lower quarter trim panel. (5) Install C-pillar upper trim cover. (6) Route seat belt webbing and turning loop through access hole in lower quarter trim panel. (7) Install B-pillar upper trim cover. (8) Install turning loop onto C-pillar. Tighten all seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (9) Press clam shell cover over seat belt turning loop. (10) Install anchor to floor. (11) Slide floor anchor cover over the anchor bolt. (12) Install shoulder harness height adjuster knob by pushing it onto adjuster. RESTRAINTS RS 8O - 9 SEAT BELT LEFT FIRST ROW OUTBOARD - SWB THREE DOOR (Continued) (11) Remove bolt attaching seat belt retractor to quarter panel (Fig. 4). (12) Lift retractor upward and disengage arrow head retainer holding retractor to quarter panel. (13) Remove seat belt from vehicle. Fig. 3 SEAT BELT LEFT FIRST ROW OUTBOARD – SWB THREE DOOR 1 2 3 4 5 - C-PILLAR TRIM KNOB RETRACTOR LOWER ANCHOR QUARTER TRIM (13) Install first and second row seats. SEAT BELT FIRST ROW OUTBOARD - SWB FOUR DOOR Fig. 4 SEAT BELT FIRST ROW OUTBOARD - SWB FOUR DOOR 1 2 3 4 5 6 7 8 - UPPER C-PILLAR TRIM KNOB HEIGHT ADJUSTER C-PILLAR RETRACTOR FLOOR ANCHOR QUARTER TRIM PANEL TURNING LOOP REMOVAL INSTALLATION (1) Remove first and second row seats. Refer to Owner’s manual for proper procedures. (2) Remove shoulder harness height adjuster knob by pulling it straight away from adjuster. (3) Slide floor anchor cover from over the anchor bolt. (4) Remove floor anchor bolt (Fig. 4). (5) Remove anchor from floor. (6) Open clam shell cover from over seat belt turning loop. (7) Remove bolt attaching turning loop to shoulder belt height adjuster (Fig. 4). (8) Remove turning loop from C-pillar. (9) Remove lower quarter trim panel. (10) Route seat belt webbing and turning loop through access hole in lower quarter trim panel. (1) Install seat belt into position. (2) Lower retractor into position to quarter panel. (3) Install bolt attaching seat belt retractor to quarter panel. Tighten seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (4) Route seat belt webbing and turning loop through access hole in lower quarter trim panel. (5) Install lower quarter trim panel. (6) Install turning loop in position on C-pillar. Tighten seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (7) Install bolt attaching turning loop to shoulder belt height adjuster. Tighten seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (8) Close clam shell cover over seat belt turning loop. (9) Place anchor in position on floor. 8O - 10 RESTRAINTS RS SEAT BELT FIRST ROW OUTBOARD - SWB FOUR DOOR (Continued) (10) Install floor anchor bolt. Tighten seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (11) Slide floor anchor cover over the anchor bolt. (12) Install shoulder harness height adjuster knob by pushing knob on the adjuster. SEAT BELT FIRST ROW OUTBOARD - LWB FOUR DOOR REMOVAL (1) Remove first and second row seats. Refer to Owner’s manual for proper procedures. (2) Remove shoulder harness height adjuster knob by pulling it straight away from adjuster. (3) Slide floor anchor cover from over the anchor bolt. (4) Remove floor anchor bolt. (5) Remove anchor from floor. (6) Open clam shell cover from over seat belt turning loop. (7) Remove bolt attaching turning loop to shoulder belt height adjuster. (8) Remove turning loop from C-pillar. (9) Remove lower quarter trim panel. (10) Route seat belt webbing and turning loop through access hole in lower quarter trim panel. (11) Remove bolt attaching seat belt retractor to quarter panel. (12) Lift retractor upward and disengage arrow head retainer attaching retractor to quarter panel. (13) Remove seat belt from vehicle. INSTALLATION (1) Position seat belt to vehicle. (2) Install arrow head retainer to quarter panel and push downward to seat retainer. (3) Install bolt attaching seat belt retractor to quarter panel. (4) Route seat belt webbing and turning loop through access hole in lower quarter trim panel. (5) Install lower quarter trim panel. (6) Position turning loop to C-pillar. (7) Install bolt attaching turning loop to shoulder belt height adjuster. (8) Close clam shell cover from over seat belt turning loop. (9) Position anchor to floor. (10) Install floor anchor bolt. (11) Slide floor anchor cover over the anchor bolt. (12) Install shoulder harness height adjuster knob by pushing it straight onto adjuster. (13) Install first and second row seats. Refer to Owner’s manual for proper procedures. NOTE: The tightening specification for all seat belt anchor bolts is 39 N·m (29 ft. lbs.) torque. SEAT BELT SECOND RIGHT ROW OUTBOARD - LWB REMOVAL (1) Remove second row seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Slide lower anchor cover from over the anchor shoulder-nut. (3) Remove lower anchor shoulder-nut (Fig. 5). (4) Remove lower anchor from wheelhouse. (5) Fold upper turning loop extension cover downward to gain access to anchor bolt. (6) Remove bolt attaching turning loop to extension bracket above quarter glass (Fig. 5). (7) Remove turning loop from extension bracket. (8) Remove D-pillar trim panel. (9) Remove quarter trim bolster. (10) Route seat belt webbing and turning loop through access hole in quarter trim. (11) Remove bolt attaching retractor to inner quarter panel (Fig. 5). (12) Remove screw attaching retractor to inner quarter panel. (13) Remove second row seat belt retractor from vehicle. INSTALLATION (1) Position second row seat belt retractor in vehicle. (2) Install screw attaching retractor to inner quarter panel. (3) Install bolt attaching retractor to inner quarter panel. Tightening specifications for all seat belt bolts is 39 N·m (29 ft. lbs.) torque. (4) Route seat belt webbing and turning loop through access hole in quarter trim. (5) Install quarter trim bolster. (6) Install D-pillar trim panel. (7) Position turning loop to extension bracket. (8) Install bolt attaching turning loop to extension bracket above quarter glass. Tightening specifications for all seat belt bolts is 39 N·m (29 ft. lbs.) torque. (9) Install upper turning loop extension cover. (10) Position lower anchor to wheelhouse. (11) Install lower anchor shoulder-nut. Tightening shoulder nut to 39 N·m (29 ft. lbs.) torque. (12) Install lower anchor cover over the anchor shoulder-nut. RESTRAINTS RS 8O - 11 SEAT BELT SECOND RIGHT ROW OUTBOARD - LWB (Continued) Fig. 5 SECOND RIGHT ROW OUTBOARD SEAT BELT - LWB 1 2 3 4 5 6 7 8 9 (10) Remove quarter trim panel as necessary to gain access to HVAC unit. (11) Route seat belt webbing and turning loop through access hole in quarter trim. (12) Loosen HVAC unit enough to gain access to seat belt retractor fasteners. (a) Remove bracket around HVAC unit (Fig. 6). (b) Remove air duct (Fig. 7). (c) Remove fasteners attaching HVAC unit to inner quarter panel (Fig. 8). (d) Remove screws attaching upper evaporator housing to lower evaporator housing. (e) Remove coolant line retaining bracket hold down bolt. (13) Remove bolts attaching seat belt guide loop to inner quarter panel. (14) Pull outward on HVAC unit and remove bolt attaching retractor to inner quarter panel. (15) Remove screw attaching retractor to inner quarter panel. (16) Remove second row seat belt retractor from vehicle. - TURNING LOOP GUIDE - RETRACTOR 2nd REAR - LOWER QUARTER TRIM - LOWER ANCHOR - RETRACTOR 1st REAR - ANCHOR BRACKET - QUARTER PANEL - C-PILLAR TRIM - HEIGHT ADJUSTER (13) Install second row seat to vehicle. Refer to Owner’s Manual for proper procedures. SEAT BELT SECOND RIGHT ROW OUTBOARD - LBW WITH REAR HVAC REMOVAL (1) Remove second row seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Slide lower anchor cover from over the anchor shoulder-nut. (3) Remove lower anchor shoulder-nut. (4) Remove lower anchor from wheelhouse. (5) Fold upper turning loop extension cover downward to gain access to anchor bolt. (6) Remove bolt attaching turning loop to extension bracket above quarter glass. (7) Remove turning loop from extension bracket. (8) Remove D-pillar trim panel. (9) Remove quarter trim bolster. Fig. 6 TRIM PANEL MOUNTING BRACKET 1 - TRIM PANEL MOUNTING BRACKET INSTALLATION (1) Position second row seat belt retractor to vehicle. (2) Install screw attaching retractor to inner quarter panel. (3) Pull outward on HVAC unit and install bolt attaching retractor to inner quarter panel. Tightening specifications for all seat belt bolts is 39 N·m (29 ft. lbs.) torque. (4) Install bolts attaching seat belt guide loop to inner quarter panel. (5) Install coolant line retaining bracket hold down bolt. 8O - 12 RESTRAINTS RS SEAT BELT SECOND RIGHT ROW OUTBOARD - LBW WITH REAR HVAC (Continued) (13) Install D-pillar trim panel. (14) Position turning loop to extension bracket. (15) Install bolt attaching turning loop to extension bracket above quarter glass. Tightening seat belt bolt to 39 N·m (29 ft. lbs.) torque. (16) Pull upper turning loop extension cover upward over anchor bolt. (17) Install lower anchor shoulder-nut. Tightening seat belt bolt to 39 N·m (29 ft. lbs.) torque. (18) Slide lower anchor cover over anchor shoulder-nut. (19) Install second row seat from vehicle. Refer to Owner’s Manual for proper procedures. Fig. 7 LOWER HEATER DUCT SEAT BELT SECOND ROW OUTBOARD - SWB 1 - LOWER HEAT DUCT MOUNTING REMOVAL (1) Remove second row seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Slide lower anchor cover from over the anchor shoulder-nut. (3) Remove lower anchor shoulder-nut. (4) Remove lower anchor from wheelhouse (Fig. 9). (5) Remove D-pillar trim panel. (6) Route seat belt webbing and turning loop through access hole in quarter trim. (7) Remove bolts attaching seat belt guide loop to inner quarter panel. (8) Remove anchor bolt attaching retractor to inner quarter panel. (9) Remove second row seat belt retractor from vehicle (Fig. 9). Fig. 8 REAR HVAC MOUNTING 1 - REAR HVAC MODULE MOUNTING 2 - REAR EVAPORATOR LOWER HOUSING 3 - REAR EVAPORATOR UPPER HOUSING (6) Install screws attaching upper evaporator housing to lower evaporator housing. (7) Install fasteners attaching HVAC unit to inner quarter panel. (8) Install air duct. (9) Install bracket around HVAC unit. (10) Route seat belt webbing and turning loop through access hole in quarter trim. (11) Install quarter trim panel as necessary to gain access to HVAC unit. (12) Install quarter trim bolster. INSTALLATION (1) Place second row seat belt retractor into position. (2) Install anchor bolt attaching retractor to inner quarter panel. Tighten all seat belts to 39 N·m (29 ft. lbs.) torque. (3) Install bolts attaching seat belt guide loop to inner quarter panel. (4) Route seat belt webbing and turning loop through access hole in quarter trim. (5) Install D-pillar trim panel. (6) Install lower anchor to the wheelhouse. (7) Install lower anchor shoulder-nut. Tighten all seat belts to 39 N·m (29 ft. lbs.) torque. (8) Slide lower anchor cover over the anchor shoulder-nut. RESTRAINTS RS 8O - 13 SEAT BELT SECOND ROW OUTBOARD - SWB (Continued) Fig. 10 SEAT BELT BUCKLE - FRONT INBOARD Fig. 9 SEAT BELT SECOND ROW OUTBOARD SWB 1 2 3 4 5 6 - QUARTER PANEL RETRACTOR QUARTER TRIM PANEL LOWER ANCHOR D-PILLAR TRIM TURNING LOOP 1 - SEAT CUSHION 2 - SEAT BELT BUCKLE 3 - SEAT TRACK SEAT BELT BUCKLE FIRST ROW QUAD BUCKET REMOVAL (9) Install second row seat into position. Refer to Owner’s Manual for proper procedures. SEAT BELT BUCKLE - FRONT INBOARD REMOVAL (1) Remove screws attaching front inboard side cover to seat cushion frame. (2) Remove side cover from vehicle. (3) Remove bolt attaching seat belt buckle to front seat track (Fig. 10). (4) Remove buckle from vehicle. INSTALLATION (1) Place buckle into position. (2) Install bolt attaching seat belt buckle to front seat track. Tighten seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (3) Install side cover into position. (4) Install screws attaching front inboard side cover to seat cushion frame. (1) Remove seat from vehicle. (2) Remove screws attaching inboard side cover to seat cushion. (3) Remove side cover from seat. (4) Remove bolts attaching recliner bracket to seat cushion. (5) Remove recliner bracket from seat. (6) Remove bolt attaching seat belt buckle to seat track (Fig. 10). (7) Remove buckle from vehicle. INSTALLATION (1) Place buckle into position. (2) Install bolt attaching seat belt buckle to seat track. Tighten all seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (3) Install recliner bracket onto the seat. (4) Install bolts attaching recliner bracket to seat cushion. (5) Install side cover from seat. (6) Install screws attaching inboard side cover to seat cushion. (7) Install seat into position. Tighten all seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. 8O - 14 RESTRAINTS RS SEAT BELT BUCKLE FIRST ROW - TWO PASSENGER BENCH REMOVAL (1) Remove (2) Remove to seat frame (3) Remove seat from vehicle. bolt attaching inboard seat belt buckle (Fig. 11). belt from seat. Fig. 12 SEAT BELT BUCKLE SECOND ROW THREE PASSENGER BENCH 1 2 3 4 - ANCHOR BOLT - SEAT BELTS - ANCHOR - RISER (2) Install bolt to attach seat belt buckle to seat rear frame rail. Tighten all seat belt bolts to 39 N·m (29 ft. lbs.) torque. Fig. 11 SEAT BELT BUCKLE FIRST ROW - TWO PASSENGER BENCH 1 2 3 4 - ANCHOR BOLT - TWO (2) PASS REAR SEAT BELT BUCKLE - RISER - REAR FRAME INSTALLATION (1) Place seat belt into position to the seat. (2) Install bolt attaching inboard seat belt buckle to seat frame. Tighten all seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (3) Install seat into position. SEAT BELT BUCKLE SECOND ROW - THREE PASSENGER BENCH REMOVAL (1) Remove bolt attaching seat belt buckle to seat rear frame rail (Fig. 12). (2) Remove seat belt buckle from seat. INSTALLATION (1) Place seat belt buckle in position on seat. SEAT BELT TENSIONER DESCRIPTION The seat belt system incorporates Seat Belt Tensioners. The tensioner is designed to hold the occupant in their respective seat by retracting the seat belt up to four inches. They are integral to the front seat belt buckles and cannot be serviced. If found defective they must be replaced. After an airbag deployment, the tensioner must be replaced. OPERATION At the onset of an impact event, each tensioner uses a pyrotechnic device which is triggered simultaneously with the airbags to rapidly retract the seat belts. With the slack removed, the occupant’s forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbags, the seat belt tensioner assembly must be replaced. The Occupant Restraint Controller (ORC) monitors the seat belt tensioner circuit resistance and reports active and stored Diagnostic Trouble Codes (DTC’s) if any problem is found. RESTRAINTS RS 8O - 15 SEAT BELT TENSIONER (Continued) Once a vehicle has been in an accident, the tensioner must be replaced along with any deployed airbags and broken or damaged parts. Refer to the proper Body Diagnostic Procedures manual for diagnosis and testing. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND SHOULD BE REPLACED. SHOULDER BELT HEIGHT ADJUSTER KNOB REMOVAL (1) Disengage clips attaching clam shell cover to seat belt turning loop and open cover. (2) Using a trim tool, pry knob from shoulder belt height adjuster (Fig. 14). SHOULDER BELT HEIGHT ADJUSTER REMOVAL (1) Remove B or C-pillar trim cover. (2) Remove screws attaching shoulder belt height adjuster to pillar. (3) Remove height adjuster from vehicle (Fig. 13). Fig. 14 SHOULDER BELT HEIGHT ADJUSTER KNOB 1 2 3 4 - KNOB HEIGHT ADJUSTER SEAT BELT TURNING LOOP SNAP-ON TRIM TOOL A179A INSTALLATION (1) Place shoulder belt height adjuster knob in position on height adjuster. (2) Push knob on until retainers engage. Fig. 13 SHOULDER BELT HEIGHT ADJUSTER 1 2 3 4 - SHOULDER HARNESS HEIGHT ADJUSTER PILLAR HOOK BUSHING INSTALLATION (1) Place height adjuster into position. (2) Install screws attaching shoulder belt height adjuster to pillar. Tighten seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. (3) Install B or C-pillar trim cover. 8O - 16 RESTRAINTS SIDE IMPACT AIRBAG CONTROL MODULE DESCRIPTION RS REMOVAL NOTE: Diagnose the SIACM using the service/diagnostic manual. The side airbag system is a safety devise designed to reduce the risk of fatality or serious injury, caused by a side impact of the vehicle. Vehicles equipped with side impact airbags use two Side Impact Airbag Control Modules (SIACM). One is located on each respective side body B-pillar. Each contains an impact sensor that senses a side impact occurrence. The SIACM communicates with the ORC via the PCI bus in order to notify the driver of any potential side airbag system problem. (1) Disconnect and isolate the battery negative cable terminal. (2) Remove the lower B-pillar trim from the appropriate side of the vehicle. Refer to Body, Interior, B-Pillar Lower Trim, Removal. (3) Remove the three SIACM retaining screws and remove the module from the vehicle. (4) Disconnect the SIACM electrical connector. OPERATION WARNING: DO NOT INSTALL THE SIACM IF THE MOUNTING LOCATION IS DEFORMED OR DAMAGED. The impact sensor provides verification of the direction and severity of the side impact. The right side SIACM controls the right seat airbag. The left side SIACM controls the left seat airbag. In the event of a side impact the appropriate SIACM will send an electronic signal to its airbag, deploying the airbag. The SIACM communicates with the Occupant Restraint Controller (ORC) via the PCI bus circuit. The accelerometer pulses are sent to a microprocessor, which contains a decision algorithm. When an impact is severe enough to require airbag protection, the SIACM microprocessor sends a signal to deploy the side airbag that completes the electrical circuits to the right or left side airbag. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. INSTALLATION (1) Connect the SIACM electrical connector. (2) Place the module in the slot on their respective B-pillar. Install the three SIACM retaining screws. Torque screws to 5.7 - 7.9 N·m (50 - 70 lbs.) CAUTION: Use the correct screws when installing the SIACM. (3) Install the lower B-pillar trim on the appropriate side of the vehicle. Refer to Body, Interior, B-Pillar Lower Trim, Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG SYSTEM FIRST. MESSAGE SYSTEMS RS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page OVERHEAD CONSOLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE - READING/ COURTESY LAMP REPLACEMENT . . . . STANDARD PROCEDURE - COMPASS CALIBRATION . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - COMPASS DEMAGNETIZING . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT . . . . . . . . . . . REMOVAL - OVERHEAD CONSOLE . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . ELECTRONIC VEHICLE INFO CENTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - ELECTRONIC VEHICLE INFORMATION CENTER .... STANDARD PROCEDURE - ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING . . . . . . . . . . . . . . . . . . .....1 .....2 .....2 .....3 .....3 .....4 .....4 .....5 .....5 .....6 .....6 .....6 .....7 OVERHEAD CONSOLE DESCRIPTION Three overhead consoles are available on RS/RG models. These are the Electronic Vehicle Information Center (EVIC), Compass Mini-Trip Computer (CMTC) or a Compass Temperature Computer (CT). All consoles are equipped with two reading/courtesy lamps and if the vehicle is equipped with a power liftgate or power sliding door(s) the overhead console will also include command switches for these features. The overhead console is mounted with one screw and two snap clips to a molded plastic retainer bracket located above the headliner. DESCRIPTION - COMPASS All the available overhead consoles on this model include Compass information. While in the compass/ temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only cali- page REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 COMPASS/MINI-TRIP COMPUTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING - COMPASS MINI-TRIP COMPUTER . . . . . . . . . . . . . . . . . . 9 REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 UNIVERSAL TRANSMITTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DIAGNOSIS AND TESTING - UNIVERSAL TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 10 AMBIENT TEMP SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR CIRCUIT . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 bration that may prove necessary is to drive the vehicle in three complete circles at 5 to 8 kilometers-perhour (3 to 5 miles-per-hour), on level ground, in not less than forty-eight seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found in this section may be required to restore proper compass operation. DESCRIPTION - TEMPERATURE All the available overhead consoles on this model include Temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled 8M - 2 MESSAGE SYSTEMS RS OVERHEAD CONSOLE (Continued) from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the electronic control modules (CT, CMTC, EVIC) memory. When the ignition switch is turned to the On position again, the electronic module will display the memory temperature for one minute; then update the display to the current average temperature reading within five minutes. The temperature function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The FCM sends temperature status messages to the module over the J1850 PCI data bus circuit. Following are general descriptions of the major components used in the overhead console. Refer to Wiring Diagrams for complete circuit schematics. OPERATION Refer to the vehicle Owner’s Manual for specific operation of each overhead console and its systems. DIAGNOSIS AND TESTING - OVERHEAD CONSOLE If the problem with the overhead console is an inaccurate or scrambled display, refer to Self-Diagnostic Test below. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB IIIt scan tool and the proper Diagnostic Procedures manual to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the J1850 Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedures. For complete circuit diagrams, refer to Overhead Console in the Wiring Diagrams section of the service manual. (1) Check the fused B(+) fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. (2) Check for battery voltage at the fused B(+) fuse in the integrated power module. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required. (3) Check the fused ignition switch output (run/ start) fuse in the integrated power module. If OK, go to Step 4. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. (4) Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the integrated power module. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. (5) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavity of the roof wire harness connector for the electronics module and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. (6) Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the roof wire harness connector for the electronics module. If OK, go to Step 7. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required. (7) Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the roof wire harness connector for the electronics module. If OK, refer to Self-Diagnostic Test later this group for further diagnosis of the electronics module and the J1850 PCI data bus circuit. If not OK, repair the open fused ignition switch output (run/start) circuit to the fuse in the integrated power module as required. SELF-DIAGNOSTIC TEST A self-diagnostic test is used to determine that the electronics module is operating properly, and that all the J1850 PCI data bus messages are being received for initial operation. Initiate the self-diagnostic test as follows: (1) With the ignition switch in the Off position, on Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles simultaneously depress and hold the STEP and the RESET buttons. On Compass Temperature Module (CT) equipped vehicles depress the C/T and the US/M push buttons. (2) Turn the ignition switch to the On position. (3) Following completion of these tests, the electronics module will display one of the following messages: a. Pass Self Test (EVIC only), PASS (CT, CMTC) - The electronics module is working properly. b. Failed Self Test (EVIC only), FAIL (CT, CMTC) - The electronics module has an internal fail- RS MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) ure. The electronics module is faulty and must be replaced. c. Failed J1850 Communication (EVIC only), BUS (CT, CMTC) - The electronics module is not receiving proper message input through the J1850 PCI data bus circuit. This can result from one or more faulty electronic modules in the vehicle, or from a faulty PCI data bus. The use of a DRB IIIt scan tool and the proper Diagnostic Procedures manual are required for further diagnosis. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth’s magnetic field strength, based on geographic location. Refer to Compass Variation Adjustment in the Service Procedures section of this group. NOTE: If the compass reading displays dashes, and only “CAL” appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Refer to Compass Demagnetizing in the Service Procedures section of this group. STANDARD PROCEDURE STANDARD PROCEDURE - READING/ COURTESY LAMP REPLACEMENT (1) Open hood, disconnect and isolate the negative battery cable remote terminal from the remote battery post. (2) Remove the reading/courtesy lamp lens. Using a trim stick, gently pry the forward edge of the reading/courtesy lamp lens outward. (3) Remove the reading/courtesy lamp socket from the overhead console. Rotate the reading/courtesy lamp socket one quarter turn counter clockwise. (4) Remove the lamp and socket assembly. (5) Reverse the above procedure to install. STANDARD PROCEDURE - COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement Electronic Modules (EVIC, CMTC, CT) must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. Refer to Compass Variation Adjustment in this group. Calibrate the compass manually as follows: (1) Turn the ignition switch to the On position. If the compass/thermometer data is not currently being displayed, momentarily depress and release the C/T push button to reach the compass/thermometer display. (2) On Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles depress the Reset push button and hold the button down until “CAL” appears in the display. This takes about ten seconds, and appears about five seconds after “VAR = XX” is displayed. On Compass Temperature Module (CT) equipped vehicles depress the C/T push button and US/M push button down until “CAL” appears in the display. This takes about ten seconds, and appears about five seconds after “VAR = XX” is displayed. (3) Release the push button(s). (4) Drive the vehicle on a level surface, away from large metal objects and power lines, through three or more complete circles at between five and eight kilometers-per-hour (three and five miles-per-hour) in not less than 48 seconds. The “CAL” message will disappear from the display to indicate that the compass is now calibrated. NOTE: If the “CAL” message remains in the display, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the calibration procedure one more time. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. 8M - 4 MESSAGE SYSTEMS RS OVERHEAD CONSOLE (Continued) STANDARD PROCEDURE - COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: (1) Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. (2) Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. (3) Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. (4) Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. (5) With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. (6) Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header (Fig. 1). The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. (7) Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. (8) Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. (9) Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. (10) With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. (11) Calibrate the compass and adjust the compass variance (Refer to 8 - ELECTRICAL/OVERHEAD CONSOLE - STANDARD PROCEDURE). Fig. 1 Roof Demagnetizing Pattern STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance setting may need to be changed. To set the compass variance: (1) Using the Variance Settings map, find your geographic location and note the zone number (Fig. 2). (2) Turn the ignition switch to the On position. If the compass/thermometer data is not currently being displayed, momentarily depress and release the C/T push button to reach the compass/thermometer display. (3) On Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles depress the Reset push button and hold the button down until “VAR = XX” appears in the display. This takes about five seconds. On Compass Temperature Module (CT) equipped vehicles depress the C/T push button and US/M push button MESSAGE SYSTEMS RS 8M - 5 OVERHEAD CONSOLE (Continued) Fig. 2 Variance Settings down until “VAR = XX” appears in the display. This takes about five seconds. (4) Release the push button(s). “VAR =XX ” will remain in the display. “XX” equals the current variance zone setting. (5) On Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles momentarily depress and release the Step push button to step through the zone numbers, until the zone number for your geographic location appears in the display. On Compass Temperature Module (CT) equipped vehicles depress the US/M push button to step through the zone numbers, until the zone number for your geographic location appears in the display. (6) On Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles momentarily depress and release the Reset push button to enter the displayed zone number into the EVIC/CMTC module memory. On Compass Temperature Module (CT) equipped vehicles depress the C/T push button to enter the displayed zone number into the electronic module memory. (7) Confirm that the correct directions are now indicated by the compass. REMOVAL - OVERHEAD CONSOLE (1) Disconnect and isolate the remote negative battery cable. (2) Remove the overhead console retaining screw, located in the front of console. (3) Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the rear of the unit. (4) Lower the overhead console far enough to access the wire harness connectors. (5) Disconnect the EVIC, CMTC or CT electronic module and the reading/courtesy lamps electrical connector. (6) Remove the overhead console from the vehicle. INSTALLATION (1) Position the overhead console in the vehicle. (2) Connect the EVIC, CMTC or CT electronic module and the reading/courtesy lamps electrical connector. (3) Using your fingertips, grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. CAUTION: DO NOT PRESS ON THE SUNGLASS STORAGE BIN DOOR. DAMAGE TO THE DOOR MAY RESULT. (4) Install the overhead console retaining screw, located in the front of console. Torque the screw to 1.2 N·m (10 in. lbs.). (5) Connect the remote negative battery cable. 8M - 6 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER DESCRIPTION The Electronic Vehicle Information Center (EVIC) is a module located in the overhead console on some models. The EVIC module features a large Vacuum Fluorescent Display (VFD) screen for displaying information, and back-lit push button switches labeled C/T (compass/thermometer), RESET, STEP, and MENU. The EVIC module contains a central processing unit and interfaces with other electronic modules in the vehicle over the Programmable Communications Interface (PCI) J1850 data bus circuit. The PCI data bus circuit allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The EVIC “Menu” push button provides the vehicle operator with a user interface, which allows the selection of several optional customer programmable electronic features to suit individual preferences. Refer to ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING in the Service Procedures section of this group for more information on the customer programmable feature options. If the vehicle is equipped with the optional universal transmitter transceiver, the EVIC will also display messages and an icon indicating when the universal transmitter transceiver is being trained, which of the three transmitter buttons is transmitting, and when the transceiver is cleared. Data input for all EVIC functions, including VFD dimming level, is received through the J1850 PCI data bus circuit. The EVIC module uses its internal programming and all of its data inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described in this group. If these tests prove inconclusive, the use of a DRBIIIt scan tool and the proper Diagnostic Procedures manual are recommended for further testing of the EVIC module and the J1850 PCI data bus circuit. The EVIC module cannot be repaired, and is available for service only as a unit. This unit includes the plastic module and display lens. If any of these components is faulty or damaged, the complete EVIC module must be replaced. RS OPERATION The EVIC has access to both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC module VFD will return to the last function being displayed before the ignition was turned to the Off position. The compass/thermometer display is the normal EVIC display. With the ignition switch in the On position, momentarily depressing and releasing the C/T (compass/thermometer) push button switch will cause the EVIC to return to the compass/thermometer/trip computer display mode from any other mode. While in the compass/thermometer/trip computer display mode, momentarily depressing and releasing the Step push button will step through the available trip computer display options. The EVIC trip computer features several functions that can be reset. The functions that can be reset are: average fuel economy, trip odometer and elapsed time. With the ignition switch in the On position and with one of the functions of the trip computer that can be reset currently displayed, depressing the Reset push button twice within three seconds will perform a global reset, and all of the trip computer information that can be reset will be reset to zero. With the ignition switch in the On position and the function that is to be reset currently displayed, momentarily depressing and releasing the Reset push button once will perform a local reset, and only the value of the displayed function will be reset to zero. A global or local reset will only occur if the function currently displayed is a function that can be reset. The distance to service function can also be reset using the local reset method, but it will reset back to the Service Interval distance that is set in the EVIC programmable features mode. Refer to ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING in the Service Procedures section of this group for more information on setting the Service Interval. For more information on the features, control functions and setting procedures for the EVIC module, see the owner’s manual in the vehicle glove box. DIAGNOSIS AND TESTING - ELECTRONIC VEHICLE INFORMATION CENTER Electronic Vehicle Information Center (EVIC) data is obtained from the Body Control Module (BCM) on the J1850 Data Bus circuit. The EVIC will display dashes (- -) for any of the screens it did not receive the bus messages. The label corresponding to the missing information will be lit. If no EVIC data is displayed, check the J1850 Data Bus circuit commu- MESSAGE SYSTEMS RS 8M - 7 ELECTRONIC VEHICLE INFO CENTER (Continued) nications and the BCM. If the brightness level is improper check the J1850 Data Bus circuit. The DRB IIIt is recommended for checking the J1850 Data Bus circuit and the BCM. Perform the EVIC self diagnosis before replacing the EVIC module. STANDARD PROCEDURE - ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING EVIC PROGRAMMING MODE Some vehicles are equipped with a Electronic Vehicle Information Center (EVIC) equipped overhead console. The Electronic Vehicle Information Center (EVIC) provides the vehicle operator with a user interface, which allows the selection of several optional customer programmable electronic features to suit individual preferences. The EVIC must be placed into its programming mode in order to view or change the programmable features. To enter the EVIC programming mode and to view or change the selected programmable features options, proceed as follows: (1) Turn the ignition switch to the On position. (2) Depress and release the Menu push button. The first item in the programmable features menu list will appear in the EVIC display. (3) Momentarily depress and release the Menu push button to step through the programmable features list. Each programmable feature and its currently selected option will appear on the EVIC display in the sequence shown in the Programmable Features list that follows. (4) Momentarily depress and release the Step push button to step through the available options for the programmable feature being displayed. (5) The option that last appears in the display with a programmable feature before exiting the programming mode, becomes the newly selected programmable feature option. (6) The EVIC exits the programming mode and returns to its normal operating mode when the C/T push button is depressed or when the end of the programmable features menu list is reached, whichever occurs first. PROGRAMMABLE FEATURES NOTE: TIRE PRESSURE MONITORING (TPM) SYSTEM INFORMATION IS NOT COVERED IN THIS SECTION OF THE SERVICE MANUAL. REFER TO THE TIRES/WHEELS SECTION OF THIS MANUAL FOR DETAILED TPM SYSTEM INFORMATION. • LANGUAGE? - The options include English, Francaise, Deutsch, Italiana, or Espanol. The default is English. All EVIC display nomenclature, including the trip computer functions, warning messages and the programmable features appear in the selected language. • DISPLAY U.S. OR METRIC? - The options include U.S. and M. The default is U.S. This feature toggles the trip computer temperature, fuel economy and odometer display readings between U.S. and metric units of measure. It also changes the odometer display in the instrument cluster. • SERVICE INTV. = - The options include from 1000 to 12000 kilometers in 1000 kilometer increments (2000 to 7500 miles in 500 mile increments). The default is 12000 kilometers (7500 miles). The selected distance becomes the interval at which the Perform Service warning message will be displayed by the EVIC. If a new distance is selected, a second programmable feature appears, RESET SERVICE DISTANCE? - The options include No and Yes. The default is Yes. When Yes is selected, the accumulated distance since the last previous Perform Service warning message will be reset to zero because the service interval has been changed. When No is selected, the distance until the next Perform Service warning message is reduced by the accumulated distance since the last previous message. • USE FACTORY SETTINGS? - The options include Yes and No. The default is Yes. When yes is selected all the programmable features will return to there defaults and the rest of the programmable features will not be displayed. If No is selected the rest of the programmable features will be displayed at there default values. This feature will automatically return to the Yes default under two conditions. First, if no programmable features are changed from there defaults. Second, if all the programmable features equal there defaults. • AUTO DOOR LOCKS? - The options include Yes and No. The default is Yes. When Yes is selected, all doors and the liftgate lock automatically when vehicle speed reaches 25 kilometers-per-hour (15 miles-per-hour). If YES is selected, a second programmable feature appears, AUTO UNLOCK ON EXIT? - The options again include Yes and No. The default is No. When Yes is selected, following each Auto Door Lock event all doors and the liftgate will automatically unlock when the driver door is opened, if the vehicle is stopped and the transmission gear selector is in Park or Neutral. The Auto Door Unlock event will only occur once following each Auto Door Lock event. • REMOTE UNLOCK - The options include Driver Door 1st and All Doors. The default is Driver Door 1st. When Diver Door 1st is selected, only the 8M - 8 MESSAGE SYSTEMS RS ELECTRONIC VEHICLE INFO CENTER (Continued) driver door unlocks when the Unlock button of the Remote Keyless Entry (RKE) transmitter is depressed once. The Unlock button of the RKE transmitter must be depressed twice to unlock all doors. When All Doors is selected, all doors unlock when the Unlock button of the RKE transmitter is depressed once. • REMOTE LINKED TO MEMORY? - This programmable feature only applies to vehicles equipped with the optional memory / heated system. The options include Yes and No. The default is No. When Yes is selected, the memory system will recall the Driver 1 or Driver 2 memory settings assigned to the RKE transmitter being used to unlock the vehicle. When No is selected, the memory system will only recall memory settings when the Driver 1 or Driver 2 push buttons of the memory switch on the driver side front door trim panel are depressed. • SOUND HORN ON LOCK? - The options include Yes and No. The default is No. When Yes is selected, a short horn chirp will provide an audible confirmation when the RKE receiver recognizes a valid Lock signal from an RKE transmitter. When No is selected, no horn chirp will occur with the RKE Lock event. This feature may be selected independent of the FLASH LIGHTS WITH LOCKS? programmable feature. • FLASH LIGHTS WITH LOCKS? - The options include Yes and No. The default is Yes. When Yes is selected, a single flash of the hazard warning lamps will provide an optical confirmation when the RKE receiver recognizes a valid Lock signal from an RKE transmitter, and two flashes of the same lamps will occur when the RKE receiver recognizes a valid Unlock signal from an RKE transmitter. When No is selected, no lamp flash will occur with the RKE Lock or Unlock event. This feature may be selected independent of the SOUND HORN ON LOCK? programmable feature. • HEADLAMP DELAY = - The options include Off, 30 Sec, 60 Sec, and 90 Sec. The default is 90 Sec. When a time interval is selected, the headlamps will remain on for that length of time when the headlamps are turned off after the ignition is turned off, or if the Auto mode is selected on vehicles with the Auto Headlamps option. When Off is selected, the headlamp delay feature is disabled. • HEADLAMPS ON WITH WIPERS? - This programmable feature only applies to vehicles equipped with the optional Auto Headlamps. The options include Yes and No. The default is No. When Yes is selected, the headlamps will turn on automatically when the windshield wipers are turned on. The headlamps will turn off when the wipers are turned off, as long as the headlamp switch is in the Auto or Off positions. When No is selected, the headlamps will only turn on if manually selected or if the Auto mode is selected and the outside ambient light levels dictate that they should be on. • RETRAIN TIRE SENSORS? - This programmable feature only applies to vehicles equipped with the optional Tire Pressure Monitoring System. The options include Yes and No. The default is No. When Yes is selected, and the menu button is depressed the EVIC will enter the training mode, starting with the left front tire. • POWER ACCESSORY DELAY? - The options include Yes and No. The default is Yes. When No is selected, the accessory powered components will turn off automatically when the ignition key is turned off. When Yes is selected, the accessory powered components will remain on for 45 seconds when the ignition key is turned off. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove overhead console. Refer to Overhead Console Removal and Installation in this section(Refer to 8 - ELECTRICAL/OVERHEAD CONSOLE REMOVAL). (3) Remove the ten screws holding the EVIC module in the overhead console. (4) Remove EVIC module from console assembly. NOTE: IF THE EVIC MODULE IS BEING REPLACED THE TIRE PRESSURE MONITORING SYSTEM (if equipped) MUST BE RETRAINED. REFER TO THE TIRES/WHEELS SECTION OF THIS MANUAL FOR DETAILED INSTRUCTIONS. INSTALLATION (1) Position the EVIC module in the overhead console. (2) Install the ten screws holding the EVIC module in the overhead console. (3) Install the overhead console (Refer to 8 ELECTRICAL/OVERHEAD CONSOLE - INSTALLATION). (4) Connect the battery negative cable. NOTE: IF THE EVIC MODULE IS BEING REPLACED THE TIRE PRESSURE MONITORING SYSTEM (if equipped) MUST BE RETRAINED. REFER TO THE TIRES/WHEELS SECTION OF THIS MANUAL FOR DETAILED INSTRUCTIONS. MESSAGE SYSTEMS RS 8M - 9 ELECTRONIC VEHICLE INFO CENTER (Continued) NOTE: IF A NEW EVIC MODULE HAS BEEN INSTALLED, THE COMPASS WILL HAVE TO BE CALIBRATED AND THE VARIANCE SET. REFER TO COMPASS VARIATION ADJUSTMENT AND COMPASS CALIBRATION IN THE SERVICE PROCEDURES SECTION OF THIS GROUP FOR THE PROCEDURES. COMPASS/MINI-TRIP COMPUTER DESCRIPTION The Compass Mini-Trip Computer (CMTC) and Compass Temperature (CT) computer are modules located in the overhead console. Vehicles are equipped with either the CMTC or the CT computers not both. The CMTC is different in the fact that it is equipped with the mini-trip feature. The CMTC, CT consists of a electronic control module with a vacuum fluorescent display (VFD) and function switches. The CMTC, CT consists of a electronic module that displays compass, trip computer (CMTC only), and temperature features. Actuating the STEP push button (CMTC only) will cause the CMTC to change mode of operation when ignition is ON. Actuating the STEP push button (CMTC only) will cause the CMTC to change mode of operation when ignition is ON. Example: • Average miles per gallon (ECO) • Distance to empty (DTE) • Instant miles per gallon (ECO) • Trip odometer (ODO) • Elapsed time (ET) • Off Actuating the C/T push button will cause the CMTC, CT to change to Compass/Temperature display. OPERATION The Compass Mini-Trip Computer (CMTC), Compass Temperature (CT) module in the overhead console has buttons used to select various functions. The CMTC, CT selector buttons will not operate until the ignition is in the RUN position. When the ignition switch is first turned to the RUN position the CMTC, CT display; • Blanks momentarily • All segments of the VFD will light for one second • Blanks momentarily • Returns to the last mode setting selected before the ignition was last switched OFF. DIAGNOSIS AND TESTING - COMPASS MINI-TRIP COMPUTER Compass Mini-Trip Computer (CMTC) and Compass Temperature (CT) data is obtained from the Body Control Module (BCM) on the J1850 Data Bus circuit. The CMTC and CT will display dashes (- -) for any of the screens it did not receive the bus messages. The label corresponding to the missing information will be lit. If no compass mini-trip computer data is displayed, check the J1850 Data Bus circuit communications and the BCM. If the brightness level is improper check the J1850 Data Bus circuit. The DRB IIIt is recommended for checking the J1850 Data Bus circuit and the BCM. Perform the CMTC, CT self diagnosis before replacing the CMTC or CT module. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove overhead console. Refer to Overhead Console Removal and Installation in this section(Refer to 8 - ELECTRICAL/OVERHEAD CONSOLE REMOVAL). (3) Remove the screws holding Compass Mini-Trip Computer module in the overhead console. (4) Remove CMTC module from console assembly. INSTALLATION (1) Position the compass mini-trip computer module in the overhead console. (2) Install the ten screws holding the compass mini-trip computer module in the overhead console. (3) Install the overhead console. Refer to Overhead Console Removal and Installation in this section. (4) Connect the battery negative cable. NOTE: If a new module has been installed, the compass will have to be calibrated and the variance set. Refer to Compass Variation Adjustment and Compass Calibration in the Service Procedures section of this group for the procedures. UNIVERSAL TRANSMITTER DESCRIPTION On some RS models a Universal Transmitter transceiver is standard factory-installed equipment. The universal transmitter transceiver is integral to the Electronic Vehicle Information Center (EVIC) and the Compass Mini-Trip Computer (CMTC), which is located in the overhead console. The only visible component of the universal transmitter are the three transmitter push buttons centered between the mod- 8M - 10 MESSAGE SYSTEMS RS UNIVERSAL TRANSMITTER (Continued) ules push buttons located just rearward of the display screen in the overhead console. The three universal transmitter push buttons are identified with one, two or three light indicators so that they be easily identified by sight or by feel. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The electronics module displays messages and a small house-shaped icon with one, two or three dots corresponding to the three transmitter buttons to indicate the status of the universal transmitter. The EVIC messages are: • Cleared Channels - Indicates that all of the transmitter codes stored in the universal transmitter have been successfully cleared. • Training - Indicates that the universal transmitter is in its transmitter learning mode. • Trained - Indicates that the universal transmitter has successfully acquired a new transmitter code. • Transmit - Indicates that a trained universal transmitter button has been depressed and that the universal transmitter is transmitting. The universal transmitter cannot be repaired, and is available for service only as a unit with the EVIC or CMTC modules. If any of these components is faulty or damaged, the complete EVIC or CMTC module must be replaced. OPERATION The universal transmitter operates on a nonswitched source of battery current so the unit will remain functional, regardless of the ignition switch position. For more information on the features, programming procedures and operation of the universal transmitter, see the owner’s manual in the vehicle glove box. DIAGNOSIS AND TESTING - UNIVERSAL TRANSMITTER If the universal transmitter is inoperative, but the Electronic Vehicle Information Center (EVIC) or Compass Mini-Trip Computer is operating normally, see the owner’s manual in the vehicle glove box for instructions on training the universal transmitter. Retrain the universal transmitter with a known good transmitter as instructed in the owner’s manual and test the universal transmitter operation again. If the unit is still inoperative, replace the faulty universal transmitter and EVIC/CMTC module as a unit. If both the universal transmitter and the EVIC/CMTC module are inoperative, refer to Overhead Console Diagnosis and Testing earlier in this group for further diagnosis. For complete circuit diagrams, refer to Overhead Console in Wiring Diagrams. AMBIENT TEMP SENSOR DESCRIPTION Ambient air temperature is monitored by the overhead console through ambient temperature messages received from the Front Control Module (FCM) over the Programmable Communications Interface (PCI) J1850 data bus circuit. The FCM receives a hard wired input from the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the headlamp mounting module grille opening, behind the radiator grille and in front of the engine compartment. Refer to Front Control Module in Electronic Control Modules. For complete circuit diagrams, refer to the appropriate wiring information. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the Front Control Module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Front Control Module. Based upon the resistance in the sensor, the Front Control Module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. The Front Control Module then sends the proper ambient temperature messages to the EVIC, CMTC over the PCI J1850 data bus. The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the Front Control Module, the Programmable Communications Interface (PCI) data bus, and a portion of the Electronics module. If any portion of the ambient temperature sensor circuit fails, the Front Control Module will self-diagnose the circuit. The ambient temperature sensor circuit can also be diagnosed by referring to Diagnosis and Testing Ambient Temperature Sensor, and Diagnosis and Testing - Ambient Temperature Sensor Circuit. If the temperature sensor and circuit are con- MESSAGE SYSTEMS RS 8M - 11 AMBIENT TEMP SENSOR (Continued) firmed to be OK, but the temperature display is inoperative or incorrect, refer to Diagnosis and Testing - Overhead Console in this group. For complete circuit diagrams, refer to the appropriate wiring information. DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR (1) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. (2) Measure the resistance of the ambient temperature sensor. At –40° C (–40° F), the sensor resistance is 336.6 kilohms. At 60° C (140° F), the sensor resistance is 2.49 kilohms. The sensor resistance should read between these two values. If OK, refer to Diagnosis and Testing - Ambient Temperature Sensor Circuit in this group. If not OK, replace the faulty ambient temperature sensor. DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR CIRCUIT (1) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the Front Control Module wire harness connector. (2) Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. (3) Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the Front Control Module wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. (4) Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the Front Control Module wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. (5) Check for continuity between the ambient temperature sensor signal circuit cavity of the Front Control Module wire harness connector and a good ground. There should be no continuity. If OK, refer to Diagnosis and Testing - Overhead Console in this group. If not OK, repair the shorted ambient temperature sensor signal circuit as required. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Raise and support vehicle on safety stands. (3) From behind front bumper fascia, remove screw holding sensor to radiator closure panel. (4) Remove sensor from vehicle. INSTALLATION (1) Position the sensor in the vehicle. (2) From behind the front bumper fascia, install the screw holding sensor to radiator closure panel. (3) Connect the battery negative cable. SPEED CONTROL RS 8P - 1 SPEED CONTROL TABLE OF CONTENTS page SPEED CONTROL DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION OPERATION . . . . . . . . . . . . . . . . . . . . OPERATION - INTERACTIVE SPEED CONTROL (4 Speed EATX Only) . . . . . DIAGNOSIS AND TESTING - ROAD TEST SPECIFICATIONS - TORQUE . . . . . . . . . CABLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL ....................... INSTALLATION . . . . . . . . . . . . . . . . . . . . SERVO DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......1 ......1 ......2 .....3 ......3 . . . . . . . . . . . . . . . . . . . . .4 .4 .4 .4 page OPERATION . . . . . REMOVAL ...... INSTALLATION . . . SWITCH DESCRIPTION . . . OPERATION . . . . . REMOVAL ...... INSTALLATION . . . VACUUM RESERVOIR DESCRIPTION . . . OPERATION . . . . . REMOVAL ...... INSTALLATION . . . .......................4 .......................4 .......................5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 .5 .5 .6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 .6 .6 .6 ......4 SPEED CONTROL DESCRIPTION The speed control system is electronically controlled and vacuum operated. The electronic control is integrated into the Powertrain Control Module. The controls are located on the steering wheel. The ON/OFF, and SET buttons are located on the left side of the airbag module. The RESUME/ACCEL, CANCEL and COAST buttons are located on the right side of the airbag module (Fig. 1). The system is designed to operate at speeds above 30 mph (48 km/h). WARNING: THE USE OF SPEED CONTROL IS NOT RECOMMENDED WHEN DRIVING CONDITIONS DO NOT PERMIT MAINTAINING A CONSTANT SPEED, SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT ARE WINDING, ICY, SNOW COVERED, OR SLIPPERY. OPERATION OPERATION When speed control is activated by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress and release the SET switch while the vehicle is moving at a speed between 25 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: • Stepping on the brake pedal • Depressing the OFF switch • Depressing the CANCEL switch. • Depressing the clutch pedal • Operating in 1st or 2nd gear (autostick, if equipped) Fig. 1 SPEED CONTROL SWITCHES - Typical 8P - 2 SPEED CONTROL RS SPEED CONTROL (Continued) NOTE: Turning the system off by depressing the OFF switch or turning off the ignition switch will erase the set speed stored in the PCM. For added safety, the speed control system is programmed to disengage for any of the following conditions: • An indication of Park or Neutral • A rapid increase rpm (indicates that the clutch has been disengaged) • Excessive engine rpm (indicates that the transmission may be in a low gear) • The speed signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) • The speed signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) • If the actual speed is greater than 20 mph over the set speed. • Autostick shifts into 1st or 2nd gear (autostick, if equipped) Once the speed control has been disengaged, depressing the RESUME switch when speed is greater than 20 mph allows the vehicle to resume control to the target speed that was stored in the PCM. While the speed control is engaged, the driver can increase the vehicle speed by depressing the ACCEL switch. The new target speed is stored in the PCM when the ACCEL switch is released. The PCM also has a 9tap-up9 feature in which target speed increases by 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate to a new lower target speed without disengaging speed control. Depress and hold the COAST switch until the desired speed is reached, then release the switch. The PCM also has a “Tap Down” feature in which target speed decreases at 1 mph for each momentary switch activation of the coast switch. OPERATION - INTERACTIVE SPEED CONTROL (4 Speed EATX Only) Interactive means that communication between the PCM and the TCM is taking place. Interactive speed control avoids unnecessary shifting for smoother, quieter operation and when downshifts are required, makes the shifts smoother. CLIMBING A GRADE DESCRIPTION When climbing a grade the interactive speed control tries to maintain the set speed by increasing the throttle opening, while inhibiting/delaying downshifts. OPERATION If opening the throttle alone cannot maintain the set speed and the vehicle speed drops more than three mph below the set speed, the transmission will downshift to third gear. If the vehicle continues to lose speed, by more than 6 mph, the transmission will downshift again to maintain the set speed. After the vehicle encounters a less-steep grade, or has crested the grade (reduced the load on the powertrain) and can maintain the set speed at a reduced throttle position, the transmission will upshift, as appropriate, until the set speed can be maintained in Overdrive. GRADE HUNTING DESCRIPTION All vehicles equipped with a four speed automatic transmission have a grade hunting feature for the 2nd to 3rd gear upshift and the 3rd to Overdrive upshift. OPERATION The TCM identifies the powertrain loading conditions and selects the proper gear to maintain the current vehicle speed. Under moderate loading conditions the transaxle will stay in 3rd gear until the top of the grade is reached or the powertrain loading is reduced. If powertrain loading is severe, the transaxle may shift into 2nd gear and remain there until powertrain loading is reduced, then a 2nd to 3rd gear upshift will be scheduled. Grade hunting features always operate regardless of whether or not the interactive speed control is engaged. If the interactive speed control is not engaged and powertrain loading is not reduced, the driver may have to completely lift off of the throttle before an upshift will occur. If the driver does lift off the throttle to induce an upshift under these conditions, vehicle speed will reduce and the Overdrive to 3rd and 3rd to 2nd gear downshifts will reoccur when the throttle is reapplied. If grade hunting is repeatedly induced by the driver, transaxle damage may result. AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION DESCRIPTION Transmission control software includes an automatic speed control overspeed reduction feature. This maintains vehicle speed at the selected set point when descending a grade. SPEED CONTROL RS 8P - 3 SPEED CONTROL (Continued) OPERATION The Transmission Control Module (TCM) first senses that the speed control is set. If the set speed is exceeded by more than 4 mph (6.5 km/hr) and the throttle is closed, the TCM causes the transaxle to downshift to THIRD gear. After downshifting, the automatic speed control resumes normal operation. To ensure that an upshift is appropriate after the set speed is reached, the TCM waits until the speed control system opens the throttle at least 6 degrees before upshifting to OVERDRIVE again. If the driver applies the brakes, canceling automatic speed control operation with the transaxle still in THIRD gear, the TCM maintains this gear until the driver opens the throttle at least 6 degrees to avoid an inappropriate upshift. The upshift is also delayed for 2.5 seconds after reaching the 6 degrees throttle opening in anticipation that the driver might open the throttle enough to require THIRD gear. This will avoid unnecessary and disturbing transmission cycling. If the automatic speed control RESUME feature is used after braking, the upshift is delayed until the set speed is achieved to reduce cycling and provide better response. tem. The cause of any speedometer problems should be corrected before proceeding. Refer to the Instrument Cluster for speedometer diagnosis. If a road test verifies an inoperative system, and the speedometer operates properly, check for: • A Diagnostic Trouble Code (DTC). If a DTC exists, conduct tests per the Powertrain Diagnostic Procedures manual. • A misadjusted brake (stop) lamp switch. This could also cause an intermittent problem. • Loose or corroded electrical connections at the servo. Corrosion should be removed from electrical terminals and a light coating of Mopar Multipurpose Grease, or equivalent, applied. • Leaking vacuum reservoir. • Loose or leaking vacuum hoses or connections. • Defective one-way vacuum check valve. • Secure attachment at both ends of the speed control servo cable. • Smooth operation of throttle linkage and throttle body air valve. • Conduct electrical test at PCM. • Failed speed control servo. Do the servo vacuum test. DIAGNOSIS AND TESTING - ROAD TEST CAUTION: When test probing for voltage or continuity at electrical connectors, care must be taken not to damage connector, terminals or seals. If these components are damaged, intermittent or complete system failure may occur. Perform a vehicle road test to verify reports of speed control system malfunction. The road test should include attention to the speedometer. Speedometer operation should be smooth and without flutter at all speeds. Flutter in the speedometer indicates a problem which might cause surging in the speed control sys- SPECIFICATIONS - TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Servo Mounting Bracket Nuts 14 10.3 123.9 Servo Mounting Bracket Bolts 14 10.3 123.9 Servo Mounting Nuts 6.7 60 8P - 4 SPEED CONTROL CABLE DESCRIPTION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. OPERATION This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. REMOVAL (1) Disconnect the negative battery cable. (2) Remove speed control cable from throttle cam by sliding clasp out hole used for throttle cable. (3) Compress the retaining tabs on the cable and slide cable out of bracket. (4) Disconnect electrical connectors and vacuum hose from servo. (5) Remove two nuts attaching speed control cable and mounting bracket to servo. (6) Pull cable away from servo to expose retaining clip and remove clip attaching cable to servo. (7) Remove speed control cable. INSTALLATION (1) Slide cable into throttle cable bracket and engage retaining tabs. (2) Rotate the throttle cam forward to the wide open position and install speed control cable clasp. (3) Rotate the throttle cam forward to the wide open position and install throttle cable clasp. (4) Install retaining clip that attaches cable to servo. (5) Insert servo studs through holes in the mounting bracket and speed control cable. (6) Install nuts, tighten to 6.7 N·m (60 in. lbs.). (7) Connect vacuum hose to servo. (8) Connect electrical connector. (9) Install servo and bracket and tighten nuts and bolt. (10) Connect negative battery cable. RS OPERATION The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Power is supplied to the servo by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded by the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. REMOVAL (1) (2) (3) ends Release hood latch and open hood. Disconnect the negative battery cable. Disconnect the throttle and speed control cable from throttle body (Fig. 2). SERVO DESCRIPTION The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: • Vacuum • Vent • Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. Fig. 2 Speed Control Cable End 1 - SPEED CONTROL VACUUM HOSE 2 - THROTTLE BODY 3 - SPEED CONTROL CABLE SPEED CONTROL RS 8P - 5 SERVO (Continued) (4) Depress lock tabs holding speed control and throttle cable casing to cable mount bracket. (5) Disconnect vacuum line from speed control servo that leads to the battery tray/vacuum reservoir. (6) Remove battery tray/vacuum reservoir, refer to the Battery section for more information (Fig. 3). (1) Install retaining clip to cable at servo. (2) Install 2 nuts at cable to servo and servo bracket, tighten to 7 N·m (60 ins. lbs.). (3) Connect electrical connector to servo. (4) Connect vacuum line to speed control servo that leads to the battery tray/vacuum reservoir. (5) Install speed control servo and bracket. (6) Install battery tray/vacuum reservoir, refer to the Battery section for more information. (7) Install speed control and throttle cable casing to cable mount bracket. (8) Connect the throttle and speed control cable ends to throttle body. (9) Connect the negative battery cable. SWITCH DESCRIPTION There are two separate switch pods that operate the speed control system and are located on the steering wheel. OPERATION Fig. 3 BATTERY TRAY/VACUUM RESERVOIR (7) Remove speed control servo and bracket (Fig. 4). The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM.The switch names are: ON, OFF, SET, COAST, RESUME, ACCEL, TAPUP, COAST, and CANCEL. Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions: ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP, TAP-DOWN, COAST, and CANCEL. Refer to the Speed Control Section for more information Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed. When the PCM receives the brake depressed input, it turns off power to the speed control servo and disengages speed control. Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. REMOVAL Fig. 4 SPEED CONTROL SERVO (8) Disconnect wire connector from speed control servo. (9) Remove speed control servo. INSTALLATION Transfer speed control cable to replacement speed control servo. The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. (1) Remove the negative battery cable. 8P - 6 SPEED CONTROL RS SWITCH (Continued) (2) Turn off ignition. (3) Remove the air bag, refer to the restraint section for more information. (4) Remove the screw from bottom of the switch. (5) Remove switch from steering wheel. (6) Disconnect two-way electrical connector. (7) Repeat for the other switch. INSTALLATION The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. (1) Connect two-way electrical connector. (2) Install switch. (3) Install screw for the switch. (4) Repeat for the other switch. (5) Install the air bag, refer to the restraint section for more information. (6) Install the negative battery cable. VACUUM RESERVOIR DESCRIPTION The vacuum reservoir is located in the engine compartment. It is made of plastic. OPERATION The reservoir stores engine vacuum. Manifold vacuum is supplied from the brake booster check valve. The speed control vacuum supply hose has a check valve at the source (brake booster) to maintain the highest available vacuum level in the servo, reservoir and vacuum hoses. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty. REMOVAL (1) Release hood latch and open hood. (2) Disconnect the negative battery cable. (3) Disconnect the vacuum line to the battery tray/ vacuum reservoir. (4) Remove battery tray/vacuum reservoir, refer to the Battery section for more information. INSTALLATION (1) Install battery tray/vacuum reservoir, refer to the Battery section for more information. (2) Connect vacuum line that leads to the battery tray/vacuum reservoir. (3) Connect the negative battery cable. LUBRICATION & MAINTENANCE RS 0-1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page LUBRICATION & MAINTENANCE SPECIFICATIONS - FLUID CAPACITIES . . . INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE OIL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - ENGINE COOLANT . . . . DESCRIPTION - FLEXIBLE FUEL ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . DESCRIPTION - FUEL REQUIREMENTS . DESCRIPTION - FUEL REQUIREMENTS DIESEL ENGINE . . . . . . . . . . . . . . . . . . . ....1 ....2 ....2 ....3 ....3 ....4 ....4 page DESCRIPTION - ENGINE OIL - DIESEL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . FLUID FILL/CHECK LOCATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION POINTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . HOISTING STANDARD PROCEDURE - HOISTING . . . . . JUMP STARTING STANDARD PROCEDURE - JUMP STARTING TOWING STANDARD PROCEDURE - TOWING . . . . . . ...6 ...6 ...6 ...6 ...6 ..7 ...8 ....6 LUBRICATION & MAINTENANCE SPECIFICATIONS - FLUID CAPACITIES DESCRIPTION SPECIFICATION Fuel Tank (Gas) 75 L (20 gal.) DESCRIPTION SPECIFICATION Cooling System** 3.3/3.8 L with Auxiliary Heater 15.4 L (16.3 qts.) Automatic Transaxle Service Fill 3.8 L (4.0 qts.) Automatic Transaxle 31TH Overhaul Fill 8.6 L (9.1 qts.) Automatic Transaxle 41TE Overhaul Fill 9.2 L (9.7 qts.) Manual Transaxle (T850 5-Speed) 2.4-2.7 L (2.5-2.9 qts.) Fuel Tank (Diesel) 75 L (20 gal.) Engine Oil* - 2.4 L 4.7 L (5.0 qts.) Engine Oil* - 3.3/3.8 L 4.0 L (4.5 qts.) Engine Oil* - 2.5 L (Diesel) 6.0 L (6.3 qts.) AWD Power Transfer Unit 1.15 L (2.4 pts.) Cooling System** - 2.4 L 10.7 L (11.4 qts.) Power Steering 1.2 L (2.5 pts.) Cooling System** - 2.5 L Turbo Diesel with Auxiliary Heater 13.8 L (14.6 qts.) AWD Bi-directional Overrunning Clutch 0.575 L (1.22 pts.) Cooling System** 3.3/3.8 L without Auxiliary Heater 12.6 L (13.4 qts.) AWD Rear Carrier 0.7 L (1.48 pts.) * (includes oil filter) ** (includes heater and recovery/reserve bottle) 0-2 LUBRICATION & MAINTENANCE RS INTERNATIONAL SYMBOLS API SERVICE GRADE CERTIFIED DESCRIPTION Use an engine oil that is API Certified. MOPARt provides engine oils, that meet or exceed this requirement. DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1). SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 2). Fig. 1 INTERNATIONAL SYMBOLS FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE OIL AND LUBRICANTS 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. When service is required, DaimlerChrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopart provides the best engineered products for servicing DaimlerChrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) • National Lubricating Grease Institute (NLGI) Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the front label of engine oil plastic bottles and the top of engine oil cans (Fig. 3). This symbol means that the oil has been certified by the American Petroleum Institute (API). DiamlerChrysler only recommend API Certified engine oils. Use Mopart engine oil or equivalent. Fig. 3 API SYMBOL LUBRICATION & MAINTENANCE RS 0-3 FLUID TYPES (Continued) GEAR LUBRICANTS SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the lubricants usage. Such as API GL-5 and SAE 75W90. LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 4) on the label. At the bottom of the NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the letter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality. Fig. 4 NLGI SYMBOL 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS SPECIALIZED LUBRICANTS AND OILS Some maintenance or repair procedures may require the use of specialized lubricants or oils. Consult the appropriate sections in this manual for the correct application of these lubricants. DESCRIPTION - 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. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less boiling 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. Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid 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. The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. DESCRIPTION - FLEXIBLE FUEL ENGINE OIL The information in this section is for Flexible Fuel Vehicles (FFV) only. These vehicles can be identified by the unique Fuel Filler Door Label that states Ethanol (E-85) or Unleaded Gasoline Only. This section only covers those subjects that are unique to these vehicles. Please refer to the other sections of this manual for information on features that are common between Flexible Fuel and gasoline only powered vehicles. ETHANOL FUEL (E-85) E-85 is a mixture of approximately 85% fuel ethanol and 15% unleaded gasoline. 0-4 LUBRICATION & MAINTENANCE RS FLUID TYPES (Continued) WARNING: Ethanol vapors are extremely flammable and could cause serious personal injury. Never have any smoking materials lit in or near the vehicle when removing the fuel filler tube cap (gas cap) or filling the tank. Do not use E-85 as a cleaning agent and never use it near an open flame. DESCRIPTION - AUTOMATIC TRANSMISSION FLUID FUEL REQUIREMENTS NOTE: All transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. The vehicle will operate on both unleaded gasoline with an octane rating of 87, or E-85 fuel, or any mixture of these two. For best results, a refueling pattern that alternates between E-85 and unleaded gasoline should be avoided. When you do switch fuels, it is recommended that • you do not switch when the fuel gauge indicates less than 1/4 full • you do not add less than 5 gallons when refueling • you operate the vehicle immediately after refueling for a period of at least 5 minutes Observing these precautions will avoid possible hard starting and/or significant deterioration in driveability during warm up. FFV STARTING The characteristics of E-85 fuel make it unsuitable for use when ambient temperatures fall below 0°F. In the range of 0°F to 32°F, you may experience an increase in the time it takes for your engine to start, and a deterioration in driveability (sags and/or hesitations) until the engine is fully warmed up. Engine Operating on E-85 Fuel If vehicle operates on E-85 fuel either full or parttime, use only Mopart Flexible Fuel 5W-30 engine oil or an equivalent that meets DaimlerChrysler Standard MS-9214. Equivalent commercial Flexible Fuel engine oils may be labeled as Multi-Fuel, Variable Fuel, Flexible Fuel, etc. These engine oils may be satisfactory if they meet the DaimlerChrysler Standard. SAE 5W-30 engine oil is preferred for use in Flexible Fuel engines. CAUTION: If Flexible Fuel engine oil is not used when using E-85 fuel, engine wear or damage may result. CRUISING RANGE Because E-85 fuel contains less energy per gallon than gasoline, you will experience an increase in fuel consumption. You can expect your MPG and your driving range to decrease by about 30% compared to gasoline operation. NOTE: Refer to the maintenance schedules for the recommended maintenance (fluid/filter change) intervals for this transaxle. TRANSMISSION FLUID Mopart ATF+4 (Automatic Transmission FluidType 9602) is required in the 41TE automatic and T850 manual transaxles. Substitute fluids can induce torque converter clutch shudder. Mopart ATF+4 (Automatic Transmission FluidType 9602) when new is red in color. The ATF 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, the ATF 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. FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals. DESCRIPTION - FUEL REQUIREMENTS Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded gasoline having an octane rating of 87. The use of premium gasoline is not recommended. The use of premium gasoline will provide no benefit over high quality regular gasoline, and in some circumstances may result in poorer performance. RS LUBRICATION & MAINTENANCE 0-5 FLUID TYPES (Continued) Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available. REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as “reformulated” gasoline. Reformulated gasoline contain oxygenates, and are specifically blended to reduce vehicle emissions and improve air quality. We strongly support the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components. GASOLINE/OXYGENATE BLENDS levels higher than allowed in the United States. MMT is prohibited in Federal and California reformulated gasoline. SULFUR IN GASOLINE If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in states adopting California emission standards, your vehicles will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may affect the performance of the vehicle’s catalytic converter. This may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. We recommend that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flashing, immediate service is required; see on-board diagnostics system section. MATERIALS ADDED TO FUEL Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle. All gasoline sold in the United States and Canada are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions. CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage critical fuel system components. CAUTION: Follow these guidelines to maintain your vehicle’s performance: MMT IN GASOLINE MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane number without MMT. Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. We recommend that gasoline free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gasoline retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasoline without MMT in Canada because MMT can be used at FUEL SYSTEM CAUTIONS • The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance, damage the emission control system, and could result in loss of warranty coverage. • An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance. • When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the temperature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. 0-6 LUBRICATION & MAINTENANCE RS FLUID TYPES (Continued) • The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these products contain high concentrations of methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels or additives is not the responsibility of DaimlerChrysler Corporation and may not be covered under the new vehicle warranty. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you. DESCRIPTION - FUEL REQUIREMENTS DIESEL ENGINE WARNING: DO NOT USE ALCOHOL OR GASOLINE AS A FUEL BLENDING AGENT. THEY CAN BE UNSTABLE UNDER CERTAIN CONDITIONS AND HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH DIESEL FUEL. Use good quality diesel fuel from a reputable supplier. For most year-round service, number 2 diesel fuel meeting ASTM specification D-975 will provide good performance. If the vehicle is exposed to extreme cold (below -18°C/0°F) or is required to operate at colder than normal conditions for prolonged periods, use climatize No. 2 diesel fuel or dilute the No. 2 diesel fuel with 50% No. 1 diesel fuel. This will provide better protection from fuel gelling or wax plugging of the fuel filters. Diesel fuel is seldom completely free of water. To prevent fuel system trouble, including fuel line freezing in winter, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided. If you buy good quality fuel and follow the cold weather advice above, fuel conditioners should not be required in your vehicle. If available in your area, a high cetane “premium” diesel fuel may offer improved cold starting and warm up performance. DESCRIPTION - ENGINE OIL - DIESEL ENGINES Use only Diesel Engine Oil meeting standard MIL2104C or API Classification CD or higher or CCML D4, D5. that meet Chrysler material standard MS-6395, be used. European Grade 10W-40 oils are also acceptable. Oils of the SAE 5W-40 or 8W-80 grade number are preferred when minimum temperatures consistently fall below -12°C. FLUID FILL/CHECK LOCATIONS DESCRIPTION The fluid check/fill point locations are located in each applicable service manual section. LUBRICATION POINTS DESCRIPTION Lubrication point locations are located in each applicable Sections. MAINTENANCE SCHEDULES DESCRIPTION 9Maintenance Schedule Information not included in this section, is located in the appropriate Owner’s Manual.9 HOISTING STANDARD PROCEDURE - HOISTING Refer to Owner’s Manual provided with vehicle for proper emergency jacking procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN THE ENGINE OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation. CAUTION: Do not position hoisting device on any suspension component, including the front suspension crossmember, the rear leaf springs, and the rear axle. Do not hoist on the front and rear bumpers, the lower liftgate crossmember, the lower radiator crossmember, the down standing flanges on the sill or the front engine mount. To assure of properly formulated engine oils, it is recommended that SAE Grade 10W-40 engine oils FOR PROPER HOIST PLACEMENT REFER TO (Fig. 5). SAE VISCOSITY GRADE LUBRICATION & MAINTENANCE RS 0-7 HOISTING (Continued) The hoisting points are identified by S.A.E. inverted triangle hoisting symbols (Fig. 5). The front hoisting points are at the bottom of the font rail below the hoisting symbol approximately 250 mm behind the front suspension crossmember. When using outboard lift hoists, verify that the hoist lift pads have been properly adjusted to eliminate contact between the hoist arm and the down standing flange on the sill. The rear hoisting points are the leaf spring front mounting brackets. The hoist pad must be positioned to pick up the flanges on the bracket, not the leaf spring. When servicing the leaf springs or the leaf spring mounting brackets, special provisions are required to support the rear of the vehicle. Position the rear hoist pads under the horizontal surface on the bottom of the sill, inboard adjacent to the flange and centered fore/aft between the jacking indicator tabs on the lower flange. DO NOT HOIST ON THE FLANGE. Place a soft pad between the hoist and the painted surface on the sill to avoid scratching the finish. JUMP STARTING STANDARD PROCEDURE - JUMP STARTING WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE). WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. WARNING: DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS BRIGHT COLOR. WARNING: DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. WARNING: DO NOT USE OPEN FLAME NEAR BATTERY WARNING: REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WARNING: WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. WARNING: REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: DO NOT ATTEMPT TO PUSH OR TOW THE VEHICLE TO START IT. THE VEHICLE CANNOT BE STARTED THIS WAY. PUSHING WITH ANOTHER VEHICLE MAY DAMAGE THE TRANSAXLE OR THE REAR OF THE VEHICLE. Fig. 5 HOISTING AND JACKING POINTS 1- DRIVE ON LIFT 2 - FRAME CONTACT LIFT (SINGLE POST) 2 - CHASSIS LIFT (NON-AXLE DUAL POST) 2 - OUTBOARD LIFT (DUAL POST) 2 - FLOOR JACK 3 - S.A.E. HOISTING SYMBOLS (1) Raise hood on disabled vehicle and visually inspect engine compartment for: • Battery cable clamp condition, clean if necessary. • Frozen battery. • Clear or bright color test indicator, if equipped. • Generator drive belt condition and tension. • Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. 0-8 LUBRICATION & MAINTENANCE RS JUMP STARTING (Continued) (2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. (3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 6). (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE). (6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. Fig. 6 JUMPER CABLE CLAMP CONNECTIONS 1 2 3 4 5 6 - BATTERY NEGATIVE TERMINAL POSITIVE JUMPER CABLE TEST INDICATOR (IF EQUIPPED) BATTERY POSITIVE TERMINAL BATTERY NEGATIVE JUMPER CABLE CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter may overheat and could fail. (7) If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 minutes), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine ground on disabled vehicle. • When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. • Disconnect RED cable clamp from battery positive terminal on disabled vehicle. TOWING STANDARD PROCEDURE - TOWING WARNINGS AND CAUTIONS WARNING: DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR TOW VEHICLE BY FRONT OR REAR BUMPER. DO NOT GO UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY ON SAFETY STANDS. DO NOT ALLOW PASSENGERS TO RIDE IN A TOWED VEHICLE. USE A SAFETY CHAIN THAT IS INDEPENDENT FROM THE TOWING ATTACHMENT DEVICE. CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle. Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use: • FWD vehicles, use of a flat bed towing device or a wheel lift is recommended (Fig. 7). • AWD vehicles, a flat bed towing device or a wheel lift and towing dolly is recommended (Fig. 7). When using a wheel lift towing device, be sure the disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees. LUBRICATION & MAINTENANCE RS 0-9 TOWING (Continued) FLAT BED TOWING TIE DOWNS CAUTION: Do not tie vehicle down by attaching chains or cables to suspension components or engine mounts, damage to vehicle can result. Fig. 7 RECOMMENDED TOWING 1 - WHEEL LIFT 2 - FLAT BED The vehicle can be tied to a flat bed device using the two pair of front slots on the bottom surface of the rails, behind the front wheels. The two pair of rear slots on the bottom of the rail between the bumper extension bolts and on the bottom of the rail just rearward of the jounce bumper. Vehicles equipped with a rear sway bar have brackets at this location. TOWING – FRONT WHEEL LIFT GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors. If the vehicle is being towed from the front, whenever possible ensure at least 10 inches road clearance to the tires. TOWING – REAR WHEEL LIFT A towed vehicle should be raised until the lifted wheels are a minimum 100 mm (4 in.) from the ground. Be sure there is at least 100 mm (4 in.) clearance between the tail pipe and the ground. If necessary, remove the wheels from the front end of the vehicle and lower the front end closer to the ground, to increase the ground clearance at the rear of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums or rotors. LOCKED VEHICLE TOWING When a locked vehicle must be towed with the front wheels on the ground, use a towing dolly or flat bed hauler. FLAT TOWING WITH TOW BAR • Three speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph) for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. • Four speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral. • AWD models should not be flat towed. For additional information, refer to RECOMMENDED TOWING EQUIPMENT in this section. If a vehicle cannot be towed with the front wheels lifted, the rear wheels can be lifted provided the following guide lines are observed. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. • On AWD vehicles, all four wheels must be free to rotate. Use towing dollies at unlifted end of vehicle. • Unlock steering column and secure steering wheel in straight ahead position with a clamp device designed for towing. • Three speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph) for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. • Four speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral. BRAKES RS 5-1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 BRAKES - BASE TABLE OF CONTENTS page BRAKES - BASE DESCRIPTION DESCRIPTION - BASE BRAKES . . . . . . . . . . . 3 DESCRIPTION - BASE BRAKES (EXPORT) . . . 3 OPERATION - BASE BRAKES ..............3 WARNING .............................4 CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STANDARD PROCEDURE - BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPECIFICATIONS BRAKE FASTENER TORQUE . . . . . . . . . . . . . 9 SPECIAL TOOLS BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . 9 BRAKE FLUID LEVEL SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 ADJUSTABLE PEDAL SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 PEDAL POSITION SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 DIAGNOSIS AND TESTING - PEDAL POSITION SENSOR . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 HYDRAULIC/MECHANICAL DESCRIPTION DESCRIPTION - DISC BRAKES (FRONT) . . . 14 DESCRIPTION - DISC BRAKES (REAR) . . . . 15 DESCRIPTION - DISC BRAKES (EXPORT) . . 15 page DESCRIPTION - DRUM BRAKES (REAR) . OPERATION OPERATION - DISC BRAKES (FRONT) . . . OPERATION - DISC BRAKES (REAR) . . . . DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER . . . . . . . . . . . . . . BRAKE LINES DESCRIPTION - BRAKE TUBES AND HOSES OPERATION - BRAKE TUBES AND HOSES . INSPECTION - BRAKE TUBES AND HOSES . BRAKE PADS/SHOES - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE SHOES (DISC/DISC BRAKES) . . . . . . . . . . . . . . . . REMOVAL - FRONT DISC BRAKE SHOES (DISC/DRUM BRAKES) . . . . . . . . . . . . . . . CLEANING - DISC BRAKE SHOES . . . . . . . . INSPECTION - DISC BRAKE SHOES . . . . . . INSTALLATION INSTALLATION - FRONT DISC BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - FRONT DISC BRAKE SHOES (DISC/DRUM BRAKES) . . . . . . . . . BRAKE PADS/SHOES - REAR DISC REMOVAL - REAR DISC BRAKE SHOES . . . CLEANING - DISC BRAKE SHOES . . . . . . . . INSPECTION - DISC BRAKE SHOES . . . . . . INSTALLATION - REAR DISC BRAKE SHOES BRAKE PADS/SHOES - REAR DRUM REMOVAL - REAR DRUM BRAKE SHOES . . INSPECTION - REAR DRUM BRAKE SHOE LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - REAR DRUM BRAKE SHOES ADJUSTMENTS ADJUSTMENT - REAR DRUM BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . 16 . . 16 . . 16 . 17 . . 17 . . 17 . . 17 . . 18 . . 18 . . 18 . . 19 . . 19 . . . . . 19 . 21 . 21 . 21 . . 22 . . 25 . 25 . . 26 5-2 BRAKES - BASE DISC BRAKE CALIPER - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE CALIPER (DISC/DISC BRAKES) . . . . . . . . . . . . . . . . . REMOVAL - FRONT DISC BRAKE CALIPER (DISC/DRUM BRAKES) . . . . . . . . . . . . . . . . DISASSEMBLY DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) . . . . . . . . DISASSEMBLY - CALIPER PISTON AND SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING - CALIPER . . . . . . . . . . . . . . . . . . INSPECTION - CALIPER . . . . . . . . . . . . . . . . . ASSEMBLY ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) . . . . . . . . ASSEMBLY - CALIPER PISTON AND SEAL . INSTALLATION INSTALLATION - FRONT DISC BRAKE CALIPER (DISC/DISC BRAKES) . . . . . . . . . . INSTALLATION - FRONT DISC BRAKE CALIPER (DISC/DRUM BRAKES). . . . . . . . . DISC BRAKE CALIPER - REAR REMOVAL - REAR DISC BRAKE CALIPER . . . DISASSEMBLY - CALIPER PISTON AND SEAL CLEANING - CALIPER . . . . . . . . . . . . . . . . . . INSPECTION - CALIPER . . . . . . . . . . . . . . . . . ASSEMBLY - CALIPER PISTON AND SEAL .. INSTALLATION - REAR DISC BRAKE CALIPER DISC BRAKE CALIPER ADAPTER REMOVAL - FRONT DISC BRAKE CALIPER ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER . . . . . . . . . . . . . . . . . . . DISC BRAKE CALIPER GUIDE PINS REMOVAL - DISC BRAKE CALIPER GUIDE PINS (DISC/DRUM BRAKES) . . . . . . . . . . . . INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (DISC/DRUM BRAKES) . . . . . . DRUM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . FLUID DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . JUNCTION BLOCK DESCRIPTION - NON-ABS JUNCTION BLOCK OPERATION - NON-ABS JUNCTION BLOCK . REMOVAL - NON-ABS JUNCTION BLOCK . . . INSTALLATION - NON-ABS JUNCTION BLOCK MASTER CYLINDER DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . RS . 26 . 26 . 27 . 27 . 28 . 28 . 28 . 28 . 29 . 30 . 30 . 31 . 32 . 32 . 32 . 33 . 34 . 34 . 34 . 34 . 35 . 35 . 35 . 35 . 35 . 36 . 36 . 36 . 36 . 37 DESCRIPTION - RHD . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - MASTER CYLINDER BLEEDING . . . . . . . . . . . . . . . REMOVAL REMOVAL - LHD . . . . . . . . . . . . . . . . . . . REMOVAL - RHD . . . . . . . . . . . . . . . . . . . DISASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) . . . . . . . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION - LHD . . . . . . . . . . . . . . . INSTALLATION - RHD . . . . . . . . . . . . . . . PEDAL - ADJUSTABLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL SYSTEM . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . PEDAL TORQUE SHAFT - RHD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . POWER BRAKE BOOSTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - LHD . . . . . . . . . . . . . . . . . . . REMOVAL - RHD . . . . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION - LHD . . . . . . . . . . . . . . . INSTALLATION - RHD . . . . . . . . . . . . . . . PROPORTIONING VALVE DESCRIPTION - PROPORTIONING VALVE (HEIGHT SENSING) . . . . . . . . . . . . . . . . . OPERATION - PROPORTIONING VALVE (HEIGHT SENSING) . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING PROPORTIONING VALVE (HEIGHT SENSING) . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - PROPORTIONING VALVE (HEIGHT SENSING) . . . . . . . . . . . . . . . . . INSTALLATION - PROPORTIONING VALVE (HEIGHT SENSING) . . . . . . . . . . . . . . . . . ROTOR DIAGNOSIS AND TESTING - BRAKE ROTOR STANDARD PROCEDURE - BRAKE ROTOR MACHINING . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - FRONT BRAKE ROTOR ..... INSTALLATION - FRONT BRAKE ROTOR . . SPECIFICATIONS BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . BRAKE ROTOR - EXPORT . . . . . . . . . . . . . . 38 . . . 38 . . . 38 . . . 39 . . . 40 . . . 40 . . . 41 . . . 41 . . . 42 . . . 42 . . . 42 . . . 43 . . . 43 . . . 45 . . . 47 . . . 47 . . . 48 . . . 49 . . . 49 . . . 50 . . . 52 . . . 53 . . . 55 . . . 56 . . . 57 . . . 57 . . . 58 . . . 59 . . 59 . . . 61 . . . 62 . . . 62 . . . 63 . . . 63 BRAKES - BASE RS SUPPORT PLATE - DRUM BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . WHEEL CYLINDERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ........................ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - EXPORT . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLES - PARKING BRAKE REMOVAL REMOVAL - PARKING BRAKE CABLE (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - PARKING BRAKE CABLE (INTERMEDIATE) . . . . . . . . . . . . . . . . . . . . REMOVAL - PARKING BRAKE CABLE (RIGHT REAR) . . . . . . . . . . . . . . . . . . . . . . REMOVAL - PARKING BRAKE CABLE (LEFT REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 . . 64 . . 65 . . 65 . . 65 . . 65 . . 66 . . 66 . . 66 . . 67 . . 67 . . 68 . . 69 INSTALLATION INSTALLATION - PARKING BRAKE CABLE (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - PARKING BRAKE CABLE (INTERMEDIATE) . . . . . . . . . . . . . . . . . . . INSTALLATION - PARKING BRAKE CABLE (RIGHT REAR) . . . . . . . . . . . . . . . . . . . . . INSTALLATION - PARKING BRAKE CABLE (LEFT REAR) . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS ADJUSTMENT - PARKING BRAKE CABLES CABLES - PARKING BRAKE (EXPORT) REMOVAL - FRONT CABLE . . . . . . . . . . . . INSTALLATION - FRONT CABLE . . . . . . . . . LEVER - PARKING BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . LEVER - PARKING BRAKE (EXPORT) REMOVAL - PARKING BRAKE LEVER AND FRONT CABLE . . . . . . . . . . . . . . . . . . . . INSTALLATION - PARKING BRAKE LEVER AND FRONT CABLE . . . . . . . . . . . . . . . . SHOES - PARKING BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS ADJUSTMENT - PARKING BRAKE SHOES 5-3 . . . 71 . . . 71 . . . 72 . . . 72 . 72 . . . 72 . . . 72 . . . 72 . . . 73 . . . 74 . . . 75 . . . 75 . . . 81 . . 83 . . 70 BRAKES - BASE DESCRIPTION DESCRIPTION - BASE BRAKES The base brake system consists of the following components: • Brake pedal • Power brake booster • Master cylinder • Brake tubes and hoses • Proportioning valve (non-ABS vehicles only) • Disc brakes • Drum brakes • Brake lamp switch • Brake fluid level switch • Parking brakes Front disc brakes control the braking of the front wheels; rear braking is controlled by rear drum brakes or rear disc brakes depending on options. The hydraulic brake system is diagonally split on both the non-antilock braking systems and antilock braking systems. That means the left front and right rear brakes are on one hydraulic circuit and the right front and left rear are on the other. For information on the brake lamp switch, (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - DESCRIPTION) Vehicles equipped with the optional antilock brake system (ABS) use a system designated Mark 20e. It is available with or without traction control. This system shares most base brake hardware used on vehicles without ABS. ABS components are described in detail in ANTILOCK BRAKE SYSTEM. DESCRIPTION - BASE BRAKES (EXPORT) Four-Wheel Disc Antilock Brakes are standard on all models. OPERATION - BASE BRAKES When a vehicle needs to be stopped, the driver applies the brake pedal. The brake pedal pushes the input rod of the power brake booster into the booster. The booster uses vacuum to ease pedal effort as force is transferred through the booster to the master cylinder. The booster’s output rod pushes in the master cylinder’s primary and secondary pistons applying hydraulic pressure through the chassis brake tubes to the brakes at each tire and wheel assembly. The parking brakes are foot-operated. When applied, the parking brake lever pulls on cables that actuate brake shoes at each rear wheel. These shoes 5-4 BRAKES - BASE RS BRAKES - BASE (Continued) come in contact with a hub mounted drum (drum for disc/drum brakes or drum-in-hat for disc/disc brakes) and hold it in place. WARNING 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. 1), for the installation of any metal fasteners into the shock tower. Because of the minimum clearance in this area (Fig. 1), installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing a vehicle, replace only with the equivalent part listed in the Mopar parts catalog. Fig. 1 Shock Tower To Spring Minimum Clearance Area 1 - SHOCK TOWER 2 - COIL SPRING 3 - NO SHEET METAL SCREWS, BOLTS, OR ANY OTHER METAL FASTENERS ARE TO BE INSTALLED INTO SHOCK TOWER IN THIS AREA. ALSO, NO HOLES ARE TO BE DRILLED INTO SHOCK TOWER IN THIS SAME AREA. CAUTION CAUTION: During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of brake rotor or drum, and external surfaces of hub and bearing assembly. CAUTION: Handling of brake rotors and calipers must be done in such a way as to avoid damage to the rotor and scratching or nicking of brake lining on the brake shoes. CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt or other metal fastener be installed in the shock tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front shock tower in the area shown in (Fig. CAUTION: Only the recommended jacking or hoisting positions for this vehicle are to be used whenever it is necessary to lift a vehicle. Failure to raise a vehicle from the recommended locations could result in lifting a vehicle by the hydraulic control unit mounting bracket. Lifting a vehicle by the hydraulic control unit mounting bracket will result in damage to the mounting bracket and the hydraulic control unit. DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM NOTE: There are three diagnosis charts following that cover the RED BRAKE WARNING INDICATOR LAMP, BRAKE NOISE and OTHER BRAKE CONDITIONS. BRAKES - BASE RS 5-5 BRAKES - BASE (Continued) RED BRAKE WARNING INDICATOR LAMP CONDITION RED BRAKE WARNING LAMP ON POSSIBLE CAUSES CORRECTION 1. Parking brake lever not fully released. 1. Release parking brake lever. 2. Parking brake warning lamp switch on parking brake lever. 2. Inspect and replace switch as necessary. 3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for leaks. Repair or replace as required. 4. Brake fluid level switch. 4. Disconnect switch wiring connector. If lamp goes out, replace switch. 5. Mechanical instrument cluster (MIC) problem. 5. Refer to appropriate Diagnostic information. 6. Amber ABS Warning Indicator Lamp also illuminated. 6. Refer to appropriate Diagnostic information. BRAKE NOISE CONDITION CLICK OR SQUAWK ON PEDAL APPLICATION POSSIBLE CAUSES CORRECTION 1. Brake lamp switch. 1. Replace switch. 2. Brake Transmission Shift Interlock Linkage. 2. Lubricate BTSI linkage. 3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if necessary. 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing. Correct as necessary. 2. Lack of lubricant on brake caliper slides. 2. Lubricate brake caliper slides. 3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes. 1. Broken or missing anti-rattle spring clips on shoes. 1. Replace brake shoes. 2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts. DISC BRAKE SQUEAK AT LOW SPEED (WHILE APPLYING LIGHT BRAKE PEDAL EFFORT) 1. Brake shoe linings. 1. Replace brake shoes. DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe support plate where shoes ride. 1. Lubricate shoe contact areas on brake shoe support plates. DRUM BRAKE CLUNK 1. Drum(s) have threaded machined braking surface. 1. Replace brake drums as necessary. DRUM BRAKE HOWL OR MOAN 1. Lack of lubricant on brake shoe support plate where shoes ride and at the anchor. 1. Lubricate shoe contact areas on brake shoe support plates and at the anchor. 2. Rear brake shoes. 2. Replace rear brake shoes. DRUM BRAKE SCRAPING OR WHIRRING 1. ABS wheel speed sensor or tone wheel. 1. Inspect, correct or replace faulty component(s). DISC BRAKE CHIRP DISC BRAKE RATTLE OR CLUNK 5-6 BRAKES - BASE RS BRAKES - BASE (Continued) CONDITION SCRAPING (METAL-TOMETAL). POSSIBLE CAUSES CORRECTION 1. Foreign object interference with brakes. 1. Inspect brakes and remove foreign object. 2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and drums. Reface or replace as necessary. OTHER BRAKE CONDITIONS CONDITION POSSIBLE CAUSES CORRECTION BRAKES CHATTER 1. Rear brake drum out of round or disc brake rotor has excessive thickness variation. 1. Isolate condition as rear or front. Reface or replace brake drums or rotors as necessary. BRAKES DRAG (FRONT OR ALL) 1. Contaminated brake fluid. 1. Check for swollen seals. Replace all system components containing rubber. 2. Binding caliper pins or bushings. 2. Replace pins and bushings. 3. Binding master cylinder. 3. Replace master cylinder. 4. Binding brake pedal. 4. Replace brake pedal. 5. Brake lamp switch not adjusted properly and mounting bracket is bent. 5. Straighten mounting bracket and replace brake lamp switch. 1. Parking brake cables binding or froze up. 1. Check cable routing. Replace cables as necessary. 2. Parking brake cable return spring not returning shoes. 2. Replace cables as necessary. 3. Service brakes not adjusted properly (rear drum brakes only). 3. Follow the procedure listed in the adjustment section. 4. Rear disc brake parking brake not properly adjusted. Adjust parking brake shoes. 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes. Repair source of contamination. 2. Improper power brake booster assist. 2. Refer to power brake booster diagnosis and testing. 1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction. 2. Low power brake booster assist (vacuum leak). 2. Refer to power brake booster diagnosis and testing. 3. Glazed brake linings. 3. Reface or replace brake rotors as necessary. Replace brake shoes. 4. Brake shoe lining transfer to brake rotor. 4. Reface or replace brake rotors as necessary. Replace brake shoes. 1. Air in brake lines. 1. Bleed brakes. 2. Rear drum brake auto-adjuster malfunctioning. 2. Inspect and replace drum brake components as necessary. Adjust rear brakes. BRAKES DRAG (REAR ONLY) BRAKES GRAB EXCESSIVE PEDAL EFFORT EXCESSIVE PEDAL TRAVEL (VEHICLE STOPS OK) BRAKES - BASE RS 5-7 BRAKES - BASE (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE PEDAL TRAVEL (ONE FRONT WHEEL LOCKS UP DURING HARD BRAKING) 1. One of the two hydraulic circuits to the front brakes is malfunctioning. 1. Inspect system for leaks. Check master cylinder for internal malfunction. PEDAL PULSATES/ SURGES DURING BRAKING 1. Rear brake drum out of round or disc brake rotor has excessive thickness variation. 1. Isolate condition as rear or front. Reface or replace brake drums or rotors as necessary. PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes. 2. Power brake booster runout (vacuum assist). 2. Check booster vacuum hose and engine tune for adequate vacuum supply. Refer to power brake booster diagnosis and testing. 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes. Repair source of contamination. 2. Inoperative proportioning valve (non-ABS vehicles). 2. Refer to proportioning valve diagnosis and testing. Replace valve as necessary. 3. Improper power brake booster assist. 3. Refer to power brake booster in the diagnosis and testing section. 1. Brake lamp switch out of adjustment. 1. Replace brake lamp switch. 2. Brake pedal binding. 2. Inspect and replace as necessary. 3. Obstruction in pedal linkage. 3. Remove obstruction. 4. Power Brake Booster not allowing pedal to return completely. 4. Replace power brake booster. 1. Frozen brake caliper piston. 1. Replace frozen piston or caliper. Bleed brakes. 2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes. Repair source of contamination. 3. Pinched brake lines. 3. Replace pinched line. 4. Leaking piston seal. 4. Replace piston seal or brake caliper. 5. Suspension problem. 5. Refer to the Suspension group. 1. Rear drum brakes or rear disc brake parking brake shoes out of adjustment. 1. Adjust rear drum brake shoes, or rear parking brake shoes on vehicles with rear disc brakes. PREMATURE REAR WHEEL LOCKUP STOP/BRAKE LAMPS STAY ON VEHICLE PULLS TO RIGHT OR LEFT ON BRAKING PARKING BRAKE EXCESSIVE HANDLE TRAVEL STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: This bleeding procedure is only for the vehicle’s base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, (Refer to 5 BRAKES - ABS - STANDARD PROCEDURE) CAUTION: Before removing the master cylinder cover, thoroughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. 5-8 BRAKES - BASE RS BRAKES - BASE (Continued) NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. • • • • Left Rear Wheel Right Front Wheel Right Rear Wheel Left Front Wheel NOTE: When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw (Fig. 2). Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. CAUTION: “Just cracking” the bleeder screw often restricts fluid flow, allowing only a slow, weak fluid discharge of fluid. This practice will NOT get all the air out. Make sure the bleeder is opened at least 1 full turn when bleeding. (3) Release the brake pedal only after the bleeder screw is closed. (4) Repeat steps 1 through 3, four or five times, at each bleeder screw in the proper sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. (5) Check pedal travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Continue to bleed system as necessary. (6) Perform a final adjustment of the rear brake shoes (when applicable), then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. PRESSURE BLEEDING PROCEDURE CAUTION: Use bleeder tank Special Tool C-3496-B or equivalent with Adapter, Special Tool 6921, to pressurize the hydraulic system for bleeding. Fig. 2 Trapped Air In Brake Fluid Line 1 - TRAPPED AIR The brakes may be manually bled or pressure bled. Refer to the appropriate following procedure. MANUAL BLEEDING PROCEDURE NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. Follow pressure bleeder manufacturer’s instructions for use of pressure bleeding equipment. (1) Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921 on the fluid reservoir of the master cylinder (Fig. 3). Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921. (2) Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. (3) Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the rear brakes. CAUTION: “Just cracking” the bleeder screw often restricts fluid flow, allowing only a slow, weak fluid discharge of fluid. This practice will NOT get all the air out. Make sure the bleeder is opened at least 1 full turn when bleeding. (1) Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. (2) Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. (4) After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. (5) Repeat the procedure at all the other remaining bleeder screws. BRAKES - BASE RS 5-9 BRAKES - BASE (Continued) N·m Ft. Lbs. In. Lbs. Brake Tube Nuts 17 — 145 Brake Hose Intermediate Bracket Bolt 12 — 105 Brake Hose-To-Caliper Mounting Bolt 47 35 — Disc Brake Caliper Guide Pin Bolts 35 26 — Disc Brake Caliper Bleeder Screw 15 — 125 Drum Brake Wheel Cylinder Mounting Bolts 8 — 75 Drum Brake Wheel Cylinder Mounting Bleeder screw 10 — 80 Drum Brake Support Plate Mounting Bolts 130 95 — Junction Block (Non-ABS Brakes) Mounting Bolts 28 21 250 Master Cylinder Mounting Nuts 25 19 225 Power Brake Booster Mounting Nuts 28 21 250 Proportioning Valve Mounting Bolts 54 40 — Proportioning Valve Axle Bracket Mounting Bolt 20 — 175 Parking Brake Lever (Pedal) Mounting Bolts And Nut 28 21 250 Wheel Mounting (Lug) Nuts 135 100 — DESCRIPTION Fig. 3 TOOL 6921 INSTALLED ON MASTER CYLINDER 1 - SPECIAL TOOL 6921 2 - FLUID RESERVOIR (6) Check pedal travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. (7) Perform a final adjustment of the rear brake shoes (when applicable), then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. SPECIFICATIONS BRAKE FASTENER TORQUE SPECIAL TOOLS DESCRIPTION N·m Ft. Lbs. In. Lbs. ABS ICU Mounting Bolts To Bracket 11 — 97 ABS ICU Mounting Bracket-To-Cradle Bolts 28 21 250 ABS CAB-To-HCU Mounting Screws 2 — 17 ABS Wheel Speed Sensor Head Mounting Bolt - Front 13 — 115 ABS Wheel Speed Sensor Head Mounting Bolt - Rear 10 — 90 Adjustable Pedal Position Sensor Mounting Screws 7.5 66 — Adjustable Pedal Module Mounting Screws 2.0 15 — BASE BRAKE SYSTEM Tubes, Master Cylinder Bleeding 6920 5 - 10 BRAKES - BASE RS BRAKES - BASE (Continued) Installer, Dust Boot C-4689 or C-4842 BRAKE FLUID LEVEL SWITCH Tubes, Master Cylinder Bleed 8358 DESCRIPTION The brake fluid level switch is located in the brake fluid reservoir of the master cylinder (Fig. 4). OPERATION Adapter, Master Cylinder Pressure Bleed Cap 6921 Dial Indicator, C-3339 The purpose of the brake fluid level switch is to provide the driver with an early warning that the brake fluid level in the master cylinder fluid reservoir has dropped below a normal level. This may indicate: • Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. • Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level switch closes to complete the red BRAKE warning indicator (lamp) circuit. This will turn on the red BRAKE warning indicator. The master cylinder fluid reservoir should be checked and refilled to the Full mark with DOT 3 brake fluid. If the brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. REMOVAL Gauge, Brake Safe-Set (1) Remove wiring harness connector from brake fluid reservoir level switch (Fig. 4). (2) Using fingers, compress the retaining tabs on the opposite end of brake fluid level switch. (3) With retaining tabs compressed, grasp the connector end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION Handle, Universal C–4171 (1) Insert brake fluid level switch into left side of brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to brake fluid reservoir. (2) Connect vehicle wiring harness connector to brake fluid level switch (Fig. 4). BRAKES - BASE RS 5 - 11 BRAKE FLUID LEVEL SWITCH (Continued) DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL SWITCH Refer to Appropriate Diagnostic Information. REMOVAL NOTE: Before proceeding, review all Steering Column and Airbag Warnings and Cautions. (Refer to 19 - STEERING/COLUMN - WARNING)(Refer to 8 ELECTRICAL/RESTRAINTS - WARNING) Fig. 4 MASTER CYLINDER AND BOOSTER 1 2 3 4 5 6 - (1) Remove battery ground cable terminal from battery negative post and isolate. (2) Under instrument panel, remove silencer panel below lower steering column cover. (3) Remove screws securing lower steering column cover/knee blocker, then remove it (Fig. 6). POWER BRAKE BOOSTER BOOSTER IDENTIFICATION LABEL FLUID LEVEL SWITCH CONNECTOR PRIMARY BRAKE TUBE NUT SECONDARY BRAKE TUBE NUT MASTER CYLINDER ADJUSTABLE PEDAL SWITCH DESCRIPTION The adjustable pedal switch is mounted on the left side of the lower steering column shroud (Fig. 5). The adjustable pedal switch adjusts the adjustable pedal assembly fore-and-aft. The pedal assembly moves in the direction the switch is actuated. Fig. 6 Lower Steering Column Cover And Reinforcement 1 - INSTRUMENT PANEL 2 - REINFORCEMENT PLATE 3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER Fig. 5 Adjustable Pedal Switch Location 1 - ADJUSTABLE PEDAL SWITCH 2 - LOWER STEERING COLUMN SHROUD (4) Disconnect parking brake release link at release handle. (5) Compress tabs on sides of data link diagnostic connector and remove it from knee blocker reinforcement plate. (6) Remove screws securing knee blocker reinforcement plate in place, then remove reinforcement plate (Fig. 6). (7) Remove screws fastening upper and lower steering column shrouds to steering column (Fig. 7). (8) Remove the lower shroud with adjustable pedal switch; disconnect switch wiring connector along left side of column as shroud is removed (Fig. 8). 5 - 12 BRAKES - BASE RS ADJUSTABLE PEDAL SWITCH (Continued) Fig. 7 Steering Column Shrouds 1 2 3 4 5 - FIXED SHROUD UPPER SHROUD CLOCKSPRING LOWER SHROUD STEERING COLUMN Fig. 8 Pedal Switch Wiring Connector 1 2 3 4 - STEERING COLUMN FIXED SHROUD BRAKE TRANSMISSION SHIFT INTERLOCK B.T.S.I. WIRING CONNECTOR PEDAL SWITCH WIRING CONNECTOR (9) Depress retainers on rear of adjustable pedal switch, then remove switch from lower shroud (Fig. 9). INSTALLATION (1) Guide adjustable pedal switch wiring through mounting hole in lower shroud. (2) Align switch retainers with notches in mounting hole and snap the switch into place (Fig. 9). (3) Connect adjustable pedal switch wiring connector along left side of column (Fig. 8). Fig. 9 Pedal Switch Retainers 1 - LOWER SHROUD INTERIOR 2 - RETAINERS (4) Install the lower shroud with adjustable pedal switch. Install screws fastening steering column shrouds to steering column (Fig. 7). (5) Install knee blocker reinforcement plate (Fig. 6). (6) Connect parking brake release link to release handle. (7) Install data link diagnostic connector to mounting hole in reinforcement plate. (8) Install lower steering column cover/knee blocker (Fig. 6). (9) Install silencer panel below lower steering column cover/knee blocker. (10) Connect ground cable to negative post of battery. (11) Connect scan tool (DRBIIIt) to data link diagnostic connector located below steering column. (12) Turn ignition key to ON position. (13) Using scan tool, check for and clear any existing adjustable pedal fault codes. (14) Test operation of adjustable pedals, memory sets and RKE (if equipped). If applicable, reset radio and clock. (15) Recheck for any fault codes. (16) Turn key to OFF and remove scan tool from vehicle. PEDAL POSITION SENSOR DESCRIPTION The pedal position sensor is part of the adjustable pedal assembly. It is mounted to the left of the brake pedal (Fig. 10). It senses the fore and aft position of the brake pedal. BRAKES - BASE RS 5 - 13 PEDAL POSITION SENSOR (Continued) (4) Move bulkhead connector toward left side of vehicle as far as its wires will allow. Do not overstress wiring. (5) Remove two mounting screws securing pedal position sensor in place (Fig. 12). Fig. 10 Pedal Position Sensor Location 1 - PEDAL POSITION SENSOR 2 - BRAKE PEDAL DIAGNOSIS AND TESTING - PEDAL POSITION SENSOR Refer to Appropriate Diagnostic Information. REMOVAL (1) Remove battery ground cable terminal from battery negative post and isolate. (2) Under instrument panel, remove silencer panel below lower steering column cover. (3) Press release tab to the left (Fig. 11), then remove bulkhead connector from bracket by pulling it toward lower steering column cover. Fig. 12 Pedal Position Sensor 1 - WIRING CONNECTOR 2 - GEAR BOX 3 - PEDAL POSITION SENSOR (6) Remove pedal position sensor from bracket. (7) Disconnect wiring connector and remove pedal position sensor. INSTALLATION (1) Connect wiring connector to pedal position sensor. NOTE: Make sure pin in pedal assembly fits into slot in sensor carriage when installing sensor. Fig. 11 Bulkhead Connector Release Tab 1 - RELEASE TAB 2 - PEDAL POSITION SENSOR 3 - BULKHEAD CONNECTOR (2) Place sensor against mounting bracket and into brake pedal (Fig. 12). Move carriage as necessary to align slot with pin. Install two mounting screws. Tighten screws to 7.5 N·m (66 in. lbs.) torque. (3) Align the bulkhead connector mounting slot with its bracket and install it, locking it in place. (4) Install silencer panel below lower steering column cover. (5) Connect ground cable to negative post of battery. (6) Connect scan tool (DRBIIIt) to data link diagnostic connector located below steering column. (7) Turn ignition key to ON position. (8) Using scan tool, check for and clear any existing adjustable pedal fault codes. (9) Test operation of adjustable pedals, memory sets (if equipped), and RKE (if equipped). If applicable, reset radio and clock. (10) Recheck for any fault codes. 5 - 14 BRAKES - BASE RS PEDAL POSITION SENSOR (Continued) (11) Turn key to OFF and remove scan tool from vehicle. (12) Road test the vehicle to ensure proper operation of the adjustable brake system. HYDRAULIC/MECHANICAL DESCRIPTION DESCRIPTION - DISC BRAKES (FRONT) Each front disc brake consists of the following components: • Brake Rotor • Brake Caliper • Brake Caliper Adapter • Shoes (Pads) There are two non-interchangeable front disc brake systems depending on whether the vehicle is equipped with rear drum or rear disc brakes. Vehicles with the front disc/rear drum brake combination utilize a system manufactured by TRW. Vehicles with front disc/rear disc brakes utilize a system manufactured by Continental Teves. Fig. 13 FRONT DISC BRAKE CALIPERS 1 2 3 4 5 6 7 8 - CONTINENTAL TEVES CALIPER (66 mm bore) TRW CALIPER (64 mm bore) GUIDE PIN BOLT GUIDE PIN AND BOOT CALIPER ADAPTER GUIDE PIN BOLT GUIDE PIN BUSHING CALIPER ADAPTER CAUTION: Components used on the disc/drum combination brakes are not interchangeable with the disc/disc combination brakes. The two different systems must not be mixed. Improper performance, noise and increased stopping distance can occur. The TRW front brake caliper is a one piece casting containing a single 64 mm diameter piston bore (Fig. 13) with a phenolic piston. The caliper mounts to a caliper adapter using two guide pin bolts that thread into guide pins slid into the caliper adapter (Fig. 14). The pins are lubricated and have boots that seal them in place in the adapter. The Continental Teves front brake caliper is a one piece casting containing a single piston 66 mm diameter bore (Fig. 13) with a phenolic piston. The caliper mounts to a caliper adapter using two guide pin bolts that thread into the caliper adapter and slide on bushings mounted in the caliper. CAUTION: TRW and Continental Teves calipers are not interchangeable. Each caliper is specifically designed for the unique brake system. If calipers are interchanged, improper performance, noise and increased stopping distance can occur. The two different brake calipers use different devices to control rattling. While the TRW brakes use spring clips that mount at the ends of the shoes in the adapters, Continental Teves brakes use a clip on the rear of the inboard pad to hold it to the piston Fig. 14 Guide Pins And Boots 1 - PINS 2 - BOOTS and a larger clip on the outside of the caliper, holding it to the adapter (Fig. 15). All brake caliper adapters mount to the steering knuckle in the same way using two mounting bolts. The brake rotors are also different depending on brake system. The TRW (disc/drum) front brakes utilize an inverted-hat style rotor. This rotor is externally vented meaning the inner most diameter of the braking disc vents to the outboard side (or face) of the rotor (Fig. 16). The Continental Teves (disc/disc) BRAKES - BASE RS 5 - 15 HYDRAULIC/MECHANICAL (Continued) DESCRIPTION - DISC BRAKES (REAR) There are several distinctive features to the rear disc brakes on this vehicle (Fig. 17). The single piston, floating caliper rear disc brake system includes a hub and bearing assembly, adapter, rotor, caliper, and brake shoes. Fig. 15 ANTI-RATTLE DEVICES ON CALIPERS 1 2 3 4 - CONTINENTAL TEVES CALIPER - TRW CALIPER - ANTI-RATTLE CLIP - ANTI-RATTLE CLIP front brakes utilize the familiar internally-vented hat style rotor. Internally-vented refers to the fact that the inner most diameter of the braking disc vents to the inboard side of the rotor (Fig. 16). CAUTION: TRW and Continental Teves brake rotors are not interchangeable. If brake rotors are interchanged, noise and wear problems can result. Fig. 17 Rear Disc Brakes 1 2 3 4 5 - CALIPER COTTER PIN ROTOR NUT RETAINER OUTER C/V JOINT This vehicle is equipped with a caliper having a 42 mm (1.65 in.) piston and uses a 15 inch solid nonvented brake rotor. The brake rotor is described as a drum-in-hat style because of its dual role as a braking disc and parking brake drum. The parking brake system on vehicles equipped with rear disc brakes consists of a small duo-servo drum brake mounted to the caliper adapter and uses the interior of the rear disc brake rotor as a drum (hat section of drum-in-hat style brake rotor). The outboard rear disc brake shoes (pads) are sideoriented. The shoes are marked indicating which side they belong on. DESCRIPTION - DISC BRAKES (EXPORT) Fig. 16 Externally and Internally Vented Rotors (Cross-Sectional View) 1 - EXTERNAL VENTS (TRW) 2 - INTERNAL VENTS (Continetal Teves) All vehicles are equipped with Four-Wheel-Disc brakes. Both 15” (BRE) and 16” (BR3) disc/disc brake systems are available. The disc brakes are manufactured by Continental Teves. The BR3 system is standard equipment on all-wheel drive and all right-hand drive models. It is optional on other models. The BR3 system features larger, externally vented front brake rotors. Although there are different disc/disc systems, they are serviced using the same service procedures. Some specifications differ. 5 - 16 BRAKES - BASE RS HYDRAULIC/MECHANICAL (Continued) DESCRIPTION - DRUM BRAKES (REAR) This vehicle’s rear wheel drum brakes are a twoshoe, internal-expanding type with an automatic adjuster screw. The automatic adjuster screw is located directly below the wheel cylinder that is mounted near the top of the brake assembly (Fig. 18). These and two brake shoes (and attaching parts) are mounted to a support plate at each rear wheel. A brake drum covers each brake assembly. sary. Fluid level should always be checked after replacing shoes. Fig. 19 Caliper Piston Seal Function For Automatic Adjustment 1 2 3 4 5 6 - PISTON CYLINDER BORE PISTON SEAL BRAKE PRESSURE OFF CALIPER HOUSING DUST BOOT PISTON SEAL BRAKE PRESSURE ON OPERATION - DISC BRAKES (REAR) Fig. 18 Drum Brake Assembly (Right Shown) 1 2 3 4 5 - WHEEL CYLINDER - BRAKE SHOE UPPER RETURN SPRING - AUTOMATIC ADJUSTER LEVER - TENSION CLIP - AUTOMATIC ADJUSTER ASSEMBLY OPERATION OPERATION - DISC BRAKES (FRONT) When the brakes are applied, fluid pressure is sent to each brake caliper. The pressure at the caliper is exerted equally against the caliper piston. The pressure applied to the piston is transmitted directly to the inboard brake shoe. This forces the shoe lining against the inner surface of the brake rotor. At the same time, fluid pressure within the caliper piston bore forces the caliper to slide inward on its guide pins. This action brings the outboard shoe lining into contact with the outer surface of the brake rotor. This pressure on both sides of the brake rotor causes friction, bringing the vehicle to a stop. When the brake pedal is released, so is the fluid pressure. The piston seal inside the caliper is designed to pull the piston back into the bore of the caliper when the brake pedal is released (Fig. 19). This action helps maintain the proper brake shoe-torotor clearance. As disc brake shoe linings wear, master cylinder reservoir brake fluid level will drop. Adjust as neces- The rear disc brakes operate similarly to front disc brakes, however, there are some features that require different service procedures. DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER The rear drum brakes on this vehicle automatically adjust when required during the normal operation of the vehicle every time the brakes are applied. Use the following procedure to test the operation of the automatic adjuster. Place the vehicle on a hoist with a helper in the driver’s seat to apply the brakes. Remove the access plug from the adjustment hole in each brake support plate to provide visual access of the brake adjuster star wheel. To eliminate the condition where maximum adjustment of the rear brake shoes does not allow the automatic adjuster to operate when tested, back the star wheel off approximately 30 notches. It will be necessary to hold the adjuster lever away from the star wheel to permit this adjustment. Have the helper apply the brakes. Upon application of the brake pedal, the adjuster lever should move down, turning the adjuster star wheel. Thus, a definite rotation of the adjuster star wheel can be observed if the automatic adjuster is working properly. If one or more adjusters do not function properly, the respective drum must be removed for adjuster servicing. BRAKES - BASE RS BRAKE LINES DESCRIPTION - BRAKE TUBES AND HOSES The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces. The flex hoses are made of reinforced rubber with fittings at each end. The primary and secondary brake tubes leading from the master cylinder to the ABS ICU Hydraulic Control Unit (HCU) or the non-ABS junction block have a special flexible section. This flexible section is required due to cradle movement while the vehicle is in motion (The ICU and non-ABS junction block are mounted to the cradle). If replacement of these lines is necessary, only the original factory brake line containing the flexible section must be used. OPERATION - BRAKE TUBES AND HOSES The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The flex hoses are made of rubber to allow for the movement of the vehicle’s suspension. 5 - 17 BRAKE PADS/SHOES - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE SHOES (DISC/DISC BRAKES) (1) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (2) Remove both front wheel and tire assemblies. (3) Begin on one side of the vehicle. (4) Remove the anti-rattle clip from the outboard side of the caliper and adapter. (5) Remove the two caliper guide pin bolts. (6) Remove caliper from caliper adapter and brake rotor. CAUTION: Supporting weight of caliper by the flexible brake fluid hose can damage the hose. (7) Using wire or cord, hang the caliper from the front strut assembly (Fig. 20). Support the caliper firmly to prevent weight of caliper from being supported by the brake fluid hose. INSPECTION - BRAKE TUBES AND HOSES Flexible rubber hose is used at both front brakes and at the rear axle. Inspection of brake hoses should be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first (every engine oil change). Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber 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. The brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components. The flexible brake tube sections used on this vehicle in the primary and secondary tubes from the master cylinder to the ABS hydraulic control unit connections must also be inspected. This flexible tubing must be inspected for kinks, fraying and contact with other components or with the body of the vehicle. Fig. 20 Stored Front Disc Brake Caliper 1 2 3 4 5 - STEERING KNUCKLE BRAKE FLEX HOSE CALIPER ASSEMBLY WIRE HANGER STRUT ASSEMBLY (8) Remove the outboard brake shoe from the caliper adapter. (9) Pull the inboard brake shoe away from the caliper piston until the retaining clip on shoe is free from the cavity in the caliper piston (Fig. 21). (10) Repeat the above procedure on other side of the vehicle. 5 - 18 BRAKES - BASE RS BRAKE PADS/SHOES - FRONT (Continued) (4) Remove the disc brake caliper from the disc brake adapter and hang 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 shoes from the disc brake caliper adapter. CLEANING - DISC BRAKE SHOES Fig. 21 Removing Inboard Shoe 1 2 3 4 5 - INBOARD BRAKE SHOE HANGER WIRE CALIPER ASSEMBLY RETAINING CLIP PISTON REMOVAL - FRONT DISC BRAKE SHOES (DISC/DRUM BRAKES) (1) Raise the vehicle. Refer to HOISTING in LUBRICATION AND MAINTENANCE. NOTE: Perform Step 2 through Step 5 on each side of the vehicle. (2) Remove the front tire and wheel assembly. (3) Remove the two brake caliper guide pin bolts (Fig. 22). 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. INSPECTION - DISC BRAKE SHOES Fig. 22 Brake Caliper Mounting (Typical) 1 2 3 4 - BRAKE HOSE - ADAPTER MOUNTING BOLTS - BANJO BOLT - CALIPER GUIDE PIN BOLTS Visually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators on the shoes (if equipped) 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 shoes from the calipers. Measure each brake shoe. The combined brake shoe and its lining material thickness should be measured at its thinnest point. • For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm (5/16 inch), they should be replaced. • For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 mm (9/32 inch), they should be replaced. • Typically, if front shoes are worn out, both fronts and rears need to be replaced. Make sure to check rears. RS BRAKES - BASE 5 - 19 BRAKE PADS/SHOES - FRONT (Continued) Replace both disc brake shoes (inboard and outboard) on each caliper. It is necessary to replace the shoes on the opposite side of the vehicle as well as the shoes failing inspection. If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in the original position they were removed from. INSTALLATION INSTALLATION - FRONT DISC BRAKE SHOES NOTE: There may be more than 1 lining material released. Make sure proper linings are being installed. (1) Begin on one side of the vehicle or the other. (2) Completely retract the caliper piston back into its bore in the brake caliper (This is required for caliper installation on the brake rotor with new brake shoes installed). (3) If applied, remove the protective paper from the noise suppression gasket on the rear of both the inner and outer brake shoe assemblies. (4) Install the new inboard brake shoe into the caliper piston by firmly pressing its retaining clip into the piston bore. Be sure the inboard brake shoe is positioned squarely against the face of the caliper piston. (5) Lubricate both adapter abutments where the shoes slide with a small amount of Mopart Dielectric grease, or equivalent. (6) Slide the new outboard brake shoe into the caliper adapter with the lining up against the outside of the brake rotor. CAUTION: Use care when installing the caliper assembly onto the caliper adapter, so the caliper guide pin bushings do not get damaged by the adapter bosses. (7) Carefully position the brake caliper over the brake rotor and adapter. (8) Install the caliper guide pin bolts and tighten to a torque of 35 N·m (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. (9) Install the caps over the caliper guide pin bolts. (10) Install the new caliper hold down spring (antirattle clip) on the outboard side of the caliper. Start the spring into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter. (11) Repeat the above procedure on other side of the vehicle. (12) Install the wheel and tire assemblies. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (13) Lower vehicle. (14) Pump the brake pedal several times. This will set the shoes to the brake rotor. (15) Check and adjust brake fluid level as necessary. (16) Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. INSTALLATION - FRONT DISC BRAKE SHOES (DISC/DRUM BRAKES) NOTE: Perform steps Step 1 through Step 5on each side of the vehicle. (1) Place the brake shoes in the adapter anti-rattle clips. (2) Completely retract the caliper piston back into the bore of the caliper. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins. (3) Install the disc brake caliper over the brake shoes on the brake caliper adapter. (4) Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig. 22). (5) Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 N·m (100 ft. lbs.). (6) Lower the vehicle. (7) Pump the brake pedal several times. This will set the shoes to the brake rotor. (8) Check and adjust the brake fluid level 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. BRAKE PADS/SHOES - REAR DISC REMOVAL - REAR DISC BRAKE SHOES (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). 5 - 20 BRAKES - BASE RS BRAKE PADS/SHOES - REAR DISC (Continued) (2) Remove rear wheel and tire assemblies from vehicle. (3) Remove the caliper to adapter guide pin bolts (Fig. 23). (5) Support caliper to prevent the weight of the caliper from damaging the flexible brake hose (Fig. 25). Fig. 25 Correctly Supported Caliper Fig. 23 Caliper Guide Pin Bolts 1 2 3 4 5 - DISC BRAKE CALIPER - ADAPTER - AXLE - GUIDE PIN BOLTS - DRIVESHAFT (AWD MODELS ONLY) (4) Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter (Fig. 24). Fig. 24 Removing/Installing Caliper 1 2 3 4 5 6 7 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST - DISC BRAKE CALIPER - ADAPTER ABUTMENT - OUTBOARD BRAKE SHOE HOLD DOWN CLIP - OUTBOARD BRAKE SHOE - ROTOR - ADAPTER 1 2 3 4 5 - WIRE - CALIPER - ADAPTER - ROTOR - INNER FENDER (6) If the brake rotor needs to be removed it can be removed by removing the retainer clips and then pulling the rotor straight off the wheel mounting studs. (7) Remove the outboard brake shoe from the caliper. Brake shoe is removed by pushing the shoe toward the piston, disengaging the two metal protrusions on the shoe back, then sliding the brake shoe off the caliper. (8) Remove inboard brake shoe from caliper. Inboard brake shoe is removed by pulling it out of the caliper piston, until the retaining clip is free of the piston (Fig. 26). BRAKES - BASE RS 5 - 21 BRAKE PADS/SHOES - REAR DISC (Continued) Fig. 26 Removing Inboard Brake Shoe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isually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators on the shoes (if equipped) 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 shoes from the calipers. Measure each brake shoe. The combined brake shoe and its lining material thickness should be measured at its thinnest point. • For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm (5/16 inch), they should be replaced. • For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 mm (9/32 inch), they should be replaced. • Typically, if front shoes are worn out, both fronts and rears need to be replaced. Make sure to check rears. Replace both disc brake shoes (inboard and outboard) on each caliper. It is necessary to replace the shoes on the opposite side of the vehicle as well as the shoes failing inspection. If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in the original position they were removed from. INSTALLATION - REAR DISC BRAKE SHOES (1) Completely retract caliper piston back into piston bore of caliper assembly. (2) Lubricate both adapter abutments where the shoes contact with a liberal amount of Mopart Multipurpose Lubricant, or equivalent. (3) If removed, install the brake rotor on the hub, making sure it is squarely seated on the face of the hub. (4) Install the inboard brake shoe into the caliper piston by firmly pressing it into the piston bore using your thumbs. Be sure inboard brake shoe is positioned squarely against the face of the caliper piston. NOTE: The outboard shoes are different left to right. They can be identified by a L or R stamped on the clip. (5) Install the outboard brake shoe on the disc brake caliper. Be sure the outboard shoe is positioned squarely against the outboard fingers of the caliper. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. (6) Carefully lower caliper and brake shoes over rotor and onto adapter, reversing the removal procedure (Fig. 24). 5 - 22 BRAKES - BASE RS BRAKE PADS/SHOES - REAR DISC (Continued) CAUTION: When installing the caliper guide pin bolts extreme caution should be taken not to crossthread the guide pin bolts. (7) Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 35 N·m (26 ft. lbs.). (8) Install the wheel and tire assembly. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (9) Lower vehicle. (4) Create slack in the rear park brake cables. Slack is created by grabbing exposed section of front park brake cable and pulling it down and rearward. Slack is maintained in the park brake cable by installing a pair of locking pliers on the park brake cable just rearward of only the rear body outrigger bracket. (Fig. 27) CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop the vehicle. (10) Pump brake pedal several times to set brake shoes to rotors. (11) Check fluid level in reservoir. (12) Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. BRAKE PADS/SHOES - REAR DRUM Fig. 27 Locked Out Park Brake Automatic Adjuster 1 - PARK BRAKE CABLE 2 - REAR BODY OUTRIGGER BRACKET 3 - LOCKING PLIERS REMOVAL - REAR DRUM BRAKE SHOES (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (2) Remove the rear wheel and tire assemblies from the vehicle. (3) Remove rear brake drum to hub retaining clips (if equipped), then remove rear brake drums. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DRUM - REMOVAL) (5) Remove adjustment lever spring (Fig. 28) from adjustment lever and front brake shoe. NOTE: When creating slack in the park brake cables by locking out the automatic adjuster, (Fig. 27) be sure that the park brake pedal is in the released (most upward) position. Fig. 28 Adjustment Lever Actuating Spring 1 2 3 4 - TRAILING BRAKE SHOE - LEADING BRAKE SHOE - AUTOMATIC ADJUSTER LEVER - ADJUSTER LEVER ACTUATING SPRING BRAKES - BASE RS 5 - 23 BRAKE PADS/SHOES - REAR DRUM (Continued) (6) Remove adjustment lever (Fig. 29) from leading brake shoe. Fig. 31 Brake Shoe Lower Return Spring Fig. 29 Adjustment Lever 1 - AUTOMATIC ADJUSTER 2 - LEADING BRAKE SHOE 3 - AUTOMATIC ADJUSTER LEVER (7) Remove the brake shoe to brake shoe lower return springs (Fig. 30) and (Fig. 31). 1 - TRAILING BRAKE SHOE 2 - LEADING BRAKE SHOE 3 - RETURN SPRING (8) Remove the tension clip (Fig. 32) attaching the upper return spring to the automatic adjuster assembly. Fig. 32 Tension Clip Attachment To Adjuster Fig. 30 Remove/Install Brake Shoe Lower Return Spring 1 2 3 4 5 - ANCHOR PLATE - LOWER BRAKE SHOE RETURN SPRING - REAR BRAKE SHOE - FRONT BRAKE SHOE - BRAKE SUPPORT PLATE 1 2 3 4 5 - WHEEL CYLINDER - BRAKE SHOE UPPER RETURN SPRING - AUTOMATIC ADJUSTER LEVER - TENSION CLIP - AUTOMATIC ADJUSTER ASSEMBLY 5 - 24 BRAKES - BASE RS BRAKE PADS/SHOES - REAR DRUM (Continued) (9) Remove the brake shoe to brake shoe upper return spring (Fig. 33). (11) Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and park brake actuating strut (Fig. 35). Remove the automatic adjuster assembly from the leading brake shoe. Fig. 33 Brake Shoe Upper Return Spring 1 - BRAKE SHOE RETURN SPRING 2 - LEADING BRAKE SHOE 3 - TRAILING BRAKE SHOE (10) Remove the trailing brake shoe assembly to brake support plate hold down spring and pin (Fig. 34) from the brake shoe assembly. Fig. 35 Trailing Brake Shoe Removal/Installation 1 2 3 4 5 - BRAKE SUPPORT PLATE LEADING BRAKE SHOE PARK BRAKE ACTUATING LEVER PARK BRAKE ACTUATING STRUT TRAILING BRAKE SHOE (12) Remove the leading brake shoe assembly to brake support plate hold down spring and pin (Fig. 36) from the brake shoe. Remove the leading brake shoe from the brake support plate. Fig. 34 Trailing Brake Shoe Hold Down Spring And Pin 1 - BRAKE SUPPORT PLATE 2 - HOLD DOWN SPRING AND PIN 3 - TRAILING BRAKE SHOE Fig. 36 Leading Brake Shoe Hold Down Spring And Pin 1 2 3 4 - PARK BRAKE ACTUATING LEVER BRAKE SUPPORT PLATE LEADING BRAKE SHOE HOLD DOWN SPRING AND PIN BRAKES - BASE RS 5 - 25 BRAKE PADS/SHOES - REAR DRUM (Continued) (13) Remove the park brake actuator (Fig. 37) from the leading brake shoe and transfer to the replacement brake shoe. Fig. 38 Brake Support Plate Contact Areas 1 - REAR BRAKE SUPPORT PLATE Fig. 37 Park Brake Actuator Plate 1 - RETAINING CLIP 2 - BRAKE SHOE ASSEMBLY 3 - ACTUATOR PLATE INSPECTION - REAR DRUM BRAKE SHOE LINING (1) Remove the tire and wheel assembly from the vehicle (2) Remove the rear brake adjusting hole plug found in the brake support. (3) Insert a thin screwdriver into brake adjusting hole to hold the adjusting lever away from the notches on the adjusting screw star wheel. (4) Insert Tool C-3784 into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake by prying down with adjusting tool. (5) Remove the rear brake drum from the rear hub and bearing assembly. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DRUM - REMOVAL) (6) Inspect brake lining for wear, shoe alignment, and or contamination from grease or brake fluid. INSTALLATION - REAR DRUM BRAKE SHOES (1) Lubricate the eight shoe contact areas on the support plate and anchor, (Fig. 38) using the required special Mopart Brake Lubricant or equivalent. (2) Install leading brake shoe on brake support plate. Install the leading brake shoe hold down spring and pin (Fig. 36) on the brake shoe. (3) Install the park brake actuator strut (Fig. 39) on the leading brake shoe. Then install the park brake actuator lever on the strut (Fig. 39). Fig. 39 Park Brake Components Assembled On Leading Brake Shoe 1 2 3 4 5 - PARK BRAKE CABLE LEADING BRAKE SHOE PARK BRAKE ACTUATING STRUT PARK BRAKE ACTUATING LEVER BRAKE SUPPORT PLATE (4) Install the automatic adjuster screw on the leading brake shoe. Then install the trailing brake shoe on the park brake actuating lever and park brake actuating strut (Fig. 35). Position trailing brake shoe on brake support plate. (5) Install the brake shoe hold down pin and spring on the trailing brake shoe (Fig. 34). (6) Install the brake shoe to brake shoe upper return spring (Fig. 33). 5 - 26 BRAKES - BASE RS BRAKE PADS/SHOES - REAR DRUM (Continued) CAUTION: When installing the tension clip on the automatic adjuster, it must be located on only the threaded area of the adjuster assembly (Fig. 32). If it is located on a non-threaded area of the adjuster, the function of the automatic adjuster will be affected. (7) Install the tension clip (Fig. 32) attaching the upper return spring to the automatic adjuster assembly. (8) Install the brake shoe to brake shoe lower return springs on the brake shoes (Fig. 30) and (Fig. 31). (9) Install automatic adjustment lever on the leading brake shoe of the rear brake assembly (Fig. 29). (10) Install the actuating spring on the automatic adjustment lever and leading brake shoe assembly (Fig. 28). (11) Verify that the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. (12) When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. (13) Adjust brake shoes assemblies so as not to interfere with brake drum installation. (14) Install the rear brake drums on the hubs. (15) Adjust rear brake shoes. (16) Install the wheel and tire assembly. (17) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (18) Lower the vehicle. (19) Push the parking brake lever (pedal) to the floor once and release pedal. This will automatically remove the slack from and correctly adjust the parking brake cables. (20) Road test vehicle. The automatic adjuster will continue the brake adjustment during the road test of the vehicle. ADJUSTMENTS ADJUSTMENT - REAR DRUM BRAKE SHOES NOTE: Normally, self-adjusting drum brakes do not require manual brake shoe adjustment. Although, in the event of a brake shoe replacement, it is advisable to make the initial adjustment manually to speed up the adjusting time. NOTE: Before raising the vehicle, verify the parking brake lever is fully released. (1) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (2) Remove rubber plug from rear brake adjusting hole in the rear brake support plate. (3) Insert a thin screwdriver through the adjusting hole in the support plate and against the star wheel of the adjusting screw. Move handle of the tool upward rotating the star wheel until a slight drag is felt when tire and wheel assembly is rotated. (4) Insert a second thin screwdriver or piece of welding rod into brake adjusting hole and push the adjusting lever out of engagement with the star wheel. Care should be taken so as not to bend adjusting lever or distort lever spring. (5) While holding the adjusting lever out of engagement, back off the star wheel just enough to ensure a free wheel with no brake shoe drag. (6) Repeat the above adjustment at the other rear wheel. (7) Install the adjusting hole rubber plugs back in the rear brake support plates. (8) Lower the vehicle. DISC BRAKE CALIPER FRONT REMOVAL REMOVAL - FRONT DISC BRAKE CALIPER (DISC/DISC BRAKES) (1) Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. (2) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (3) Remove front wheel and tire assembly. (4) Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. (5) Remove the 2 caliper guide pin bolts. (6) Remove the brake caliper from the adapter. REMOVAL - FRONT DISC BRAKE CALIPER (DISC/DRUM BRAKES) (1) Using a brake pedal holding tool, 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 BRAKES - BASE RS 5 - 27 DISC BRAKE CALIPER - FRONT (Continued) allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. (2) Raise the vehicle. Refer to HOISTING in LUBRICATION AND MAINTENANCE. (3) Remove the front tire and wheel assembly. (4) Remove the banjo bolt connecting the brake hose to the brake caliper (Fig. 40). There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard the washers. DISASSEMBLY - CALIPER PISTON AND SEAL 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. NOTE: Before disassembling the brake caliper, clean and inspect it. Refer to CLEANING AND INSPECTION in this section. NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle’s brake system. Fig. 40 Brake Caliper Mounting (Typical) 1 2 3 4 - BRAKE HOSE - ADAPTER MOUNTING BOLTS - BANJO BOLT - CALIPER GUIDE PIN BOLTS (1) Following the removal procedure in DISC BRAKE SHOES found in this section, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. (2) Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. (3) Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. (5) Remove the two brake caliper guide pin bolts (Fig. 40). (6) Remove the disc brake caliper from the disc brake adapter. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. DISASSEMBLY (4) Mount the caliper in a vise equipped with protective jaws. (5) Remove the piston dust boot from the caliper and discard. DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) Before disassembling the brake caliper, clean and inspect it. Refer to CLEANING or INSPECTION in this section. (1) Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. (2) Repeat this procedure on the remaining bushing. NOTE: 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, work the piston seal out of its groove in caliper piston bore (Fig. 41). Discard the old seal. (7) Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. (8) Inspect the piston 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. 5 - 28 BRAKES - BASE RS DISC BRAKE CALIPER - FRONT (Continued) osene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: • Brake fluid leaks in and around boot area and inboard lining • Ruptures, brittleness or damage to the piston dust boot • Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES) (1) Fold the guide pin bushing in half lengthwise. Fig. 41 Removing Piston Seal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o clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopart Non-Chlorinated Brake Parts Cleaner. Never use gasoline, ker- NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. (2) Insert the folded bushing into the caliper mounting boss using your fingers from the rear of the caliper. (3) Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. (4) Lubricate inside surfaces of bushing using Mopart Dielectric Grease or equivalent. (5) Repeat the procedure for remaining bushing. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. (1) Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove (Fig. 42)using only your clean fingers to seat it. (2) Coat the new piston boot with clean brake fluid. (3) Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. (4) Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 43). BRAKES - BASE RS 5 - 29 DISC BRAKE CALIPER - FRONT (Continued) Fig. 42 Installing New Piston Seal 1 - CALIPER 2 - PISTON SEAL 3 - SEAL GROOVE Fig. 44 Installing Dust Boot 1 2 3 4 - HAMMER SPECIAL TOOL C-4171 SPECIAL TOOL C-4689 or C-4842 CALIPER INSTALLATION INSTALLATION - FRONT DISC BRAKE CALIPER (DISC/DISC BRAKES) CAUTION: TRW and Continental Teves brake calipers are not interchangeable. Each caliper is specifically designed for the unique brake system (TRW disc/drum brake combination and Continental Teves - disc/disc brake combination). If calipers are interchanged, improper performance, noise and increased stopping distance can occur. Fig. 43 Installing Piston Into Caliper Bore 1 - BOOT 2 - PISTON 3 - CALIPER (5) Position the dust boot into the counterbore of the caliper assembly piston bore. (6) Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary (Fig. 44). (7) Reinstall the caliper on the vehicle and bleed the brakes as necessary. Refer to Installation in this section. (1) Completely retract the caliper piston back into piston bore of the caliper. Use a C-clamp to retract the piston if necessary. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. CAUTION: Use care when installing the brake caliper assembly onto the steering knuckle, so that the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. (2) Carefully position the brake caliper and shoes over the brake rotor and adapter. (3) Install the caliper guide pin bolts and tighten to a torque of 35 N·m (26 ft. lbs.). Extreme caution 5 - 30 BRAKES - BASE RS DISC BRAKE CALIPER - FRONT (Continued) should be taken not to cross thread the caliper guide pin bolts. (4) Install the anti-rattle clip on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter. CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special copper washers. (5) Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 47 N·m (35 ft. lbs.). (6) Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (7) Lower the vehicle. (8) Remove the brake pedal depressor (holding) tool. (9) Bleed the hydraulic brake circuit to the brake caliper. (Refer to 5 - BRAKES - STANDARD PROCEDURE) (10) Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. INSTALLATION - FRONT DISC BRAKE CALIPER (DISC/DRUM BRAKES) CAUTION: TRW and Continental Teves brake calipers are not interchangeable. Each caliper is specifically designed for the unique brake system (TRW disc/drum brake combination and Continental Teves - disc/disc brake combination). If calipers are interchanged, improper performance, noise and increased stopping distance can occur. (1) Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston if necessary. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins. (2) Install the disc brake caliper over the brake shoes on the brake caliper adapter. (3) Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig. 40). (4) Install the banjo bolt connecting the brake hose to the brake caliper (Fig. 40). Install NEW copper washers 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 a torque of 47 N·m (35 ft. lbs.). (5) Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 N·m (100 ft. lbs.). (6) Lower the vehicle. (7) Remove the brake pedal holding tool. (8) Bleed the caliper as necessary. (Refer to 5 BRAKES - BASE - STANDARD PROCEDURE). (9) Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. DISC BRAKE CALIPER - REAR REMOVAL - REAR DISC BRAKE CALIPER NOTE: Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and scratching or nicking of lining on the brake shoes. (1) Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. (2) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (3) Remove rear wheel and tire assembly from vehicle. (4) Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. (5) Remove the disc brake caliper to adapter guide pin bolts (Fig. 45). (6) Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter (Fig. 46). (7) If the brake rotor requires removal, it can now be removed by first removing the retainer clips from the wheel mounting studs, then pulling the rotor straight off the studs. BRAKES - BASE RS 5 - 31 DISC BRAKE CALIPER - REAR (Continued) NOTE: Before disassembling the brake caliper, clean and inspect it. Refer to CLEANING AND INSPECTION in this section. NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle’s brake system. Fig. 45 Caliper Guide Pin Bolts 1 2 3 4 5 - DISC BRAKE CALIPER - ADAPTER - AXLE - GUIDE PIN BOLTS - DRIVESHAFT (AWD MODELS ONLY) (1) Following the removal procedure in DISC BRAKE SHOES found in this section, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. (2) Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. (3) Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. (4) Mount the caliper in a vise equipped with protective jaws. (5) Remove the piston dust boot from the caliper and discard. NOTE: 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. Fig. 46 Removing/Installing Caliper 1 2 3 4 5 6 7 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST - DISC BRAKE CALIPER - ADAPTER ABUTMENT - OUTBOARD BRAKE SHOE HOLD DOWN CLIP - OUTBOARD BRAKE SHOE - ROTOR - ADAPTER DISASSEMBLY - CALIPER PISTON AND SEAL 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. (6) Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore (Fig. 47). Discard the old seal. (7) Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. (8) Inspect the piston 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. 5 - 32 BRAKES - BASE RS DISC BRAKE CALIPER - REAR (Continued) osene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: • Brake fluid leaks in and around boot area and inboard lining • Ruptures, brittleness or damage to the piston dust boot • Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. Fig. 47 Removing Piston Seal 1 2 3 4 - PLASTIC TRIM STICK CALIPER PISTON SEAL GROOVE PISTON SEAL (1) Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove (Fig. 48)using only your clean fingers to seat it. CLEANING - CALIPER 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 Mopart Non-Chlorinated Brake Parts Cleaner. Never use gasoline, ker- Fig. 48 Installing New Piston Seal 1 - CALIPER 2 - PISTON SEAL 3 - SEAL GROOVE (2) Coat the new piston boot with clean brake fluid. (3) Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. (4) Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 49). BRAKES - BASE RS 5 - 33 DISC BRAKE CALIPER - REAR (Continued) Fig. 49 Installing Piston Into Caliper Bore 1 - BOOT 2 - PISTON 3 - CALIPER (5) Position the dust boot into the counterbore of the caliper assembly piston bore. (6) Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary (Fig. 50). (7) Reinstall the caliper on the vehicle and bleed the brakes as necessary. Refer to Installation in this section. INSTALLATION - REAR DISC BRAKE CALIPER (1) Completely retract caliper piston back into piston bore of the caliper. (2) If removed, install the brake rotor on the hub, making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. (3) Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal (Fig. 46). CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts. (4) Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 35 N·m (26 ft. lbs.). Fig. 50 Installing Dust Boot 1 2 3 4 - HAMMER SPECIAL TOOL C-4171 SPECIAL TOOL C-4689 or C-4842 CALIPER CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special washers. (5) Install the brake hose on the caliper. To do this, first place one NEW special copper washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 47 N·m (35 ft. lbs.). (6) Install the wheel and tire assembly. (7) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (8) Lower the vehicle. (9) Remove the brake pedal depressor (holding) tool. (10) Bleed the hydraulic brake circuit to the brake caliper. (Refer to 5 - BRAKES - STANDARD PROCEDURE) (11) Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. 5 - 34 BRAKES - BASE RS DISC BRAKE CALIPER ADAPTER REMOVAL - FRONT DISC BRAKE CALIPER ADAPTER (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove front wheel and tire assembly, disc brake caliper and brake shoes. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - REMOVAL) (3) Remove two bolts fastening adapter to steering knuckle, then remove disc brake caliper adapter. INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER (1) Place adapter over brake rotor and align adapter mounting holes to knuckle. Fig. 51 Brake Caliper Mounting 1 2 3 4 - BRAKE HOSE - ADAPTER MOUNTING BOLTS - BANJO BOLT - CALIPER GUIDE PIN BOLTS CAUTION: Adapter mounting bolts have a special DacrometT coating applied to resist corrosion. If mounting bolts need to be replaced, use only MoparT replacement parts. (2) Install adapter mounting bolts and tighten to 169 N·m (125 ft. lbs.) torque. (3) Install brake shoes, disc brake caliper and wheel and tire assembly. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES INSTALLATION) (4) Lower vehicle. (5) Pump the brake pedal several times to set the pads to the brake rotor. (6) Check and adjust brake fluid level as necessary. DISC BRAKE CALIPER GUIDE PINS Fig. 52 Guide Pins And Boots 1 - PINS 2 - BOOTS REMOVAL - DISC BRAKE CALIPER GUIDE PINS (DISC/DRUM BRAKES) INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (DISC/DRUM BRAKES) (1) Raise the vehicle. Refer to HOISTING in LUBRICATION AND MAINTENANCE. (2) Remove the front tire and wheel assembly. (3) Remove the two brake caliper guide pin bolts (Fig. 51). (4) Remove the disc brake caliper from the disc brake caliper adapter 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 guide pins and boots from the adapter as shown (Fig. 52). (1) Lubricate the guide pins and inside the boots with the packet supplied with the service kit, Sytheso GLK-1 lubricant or equivalent. (2) Install the guide pins and boots in the adapter as shown (Fig. 52). The boots have grooves built into their inner lips to fit onto the pins and adapter. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins. BRAKES - BASE RS 5 - 35 DISC BRAKE CALIPER GUIDE PINS (Continued) (3) Install the disc brake caliper over the brake shoes on the brake caliper adapter. (4) Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig. 51). (5) Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 N·m (100 ft. lbs.). (6) Lower the vehicle. (7) Pump the brake pedal several times before moving the vehicle to set the shoes to the brake rotor. DRUM REMOVAL (1) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (2) Remove the tire and wheel assembly from the vehicle (3) Remove the rear brake shoe adjusting hole cover plug. (4) Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of adjusting screw star wheel. (5) Insert another thin screwdriver into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake adjustment by prying down with adjusting tool. (6) Remove rear brake drum from rear hub/bearing assembly. NOTE: It may be necessary to insert M8 X 1.25 MM bolts into the two removal holes on the drum to force the drum off the hub. INSTALLATION (1) Adjust brake shoe assemblies so as not to interfere with brake drum installation. (2) Install the rear brake drums on the hubs. (3) Adjust drum brake shoes as necessary per procedure found in the Adjustment section of this service manual group (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/DRUM ADJUSTMENTS). (4) Install wheel and tire assembly. (5) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (6) Lower the vehicle. FLUID DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brake hydraulic unit and all hydraulic fluid hoses. STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING Check master cylinder reservoir fluid level a minimum of twice annually. Fluid reservoirs are marked with the words FULL and ADD to indicate proper brake fluid fill level of the master cylinder. If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the master cylinder fluid reservoir. Use only Mopart brake fluid or equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications (DOT 4 or DOT 4+ are acceptable). DO NOT use brake fluid with a lower boiling point, as brake failure could result during prolonged hard braking. Use only brake fluid that was stored in a tightlysealed container. DO NOT use petroleum-based fluid because seal damage will result. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid etc. SPECIFICATIONS BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications (DOT 4 and DOT 4+ are acceptable) and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopart Brake Fluid or equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. 5 - 36 BRAKES - BASE RS FLUID (Continued) (c) Disconnect the vacuum hose connector at the tank built into the battery tray. (d) Remove the screw securing the coolant filler neck to the battery tray. (e) Remove the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - REMOVAL). (f) Remove the fasteners and move the speed control servo off to the side, out of the way. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. JUNCTION BLOCK DESCRIPTION - NON-ABS JUNCTION BLOCK A junction block is used on vehicles that are not equipped with antilock brakes (ABS). The junction block mounts in the same location as the integrated control unit (ICU) does on vehicles equipped with ABS. This allows for use of the same brake tube configuration on all vehicles. The junction block is located on the driver’s side of the front suspension cradle/crossmember below the master cylinder (Fig. 53). It has six threaded ports to which the brake tubes connect. Two are for the primary and secondary brake tubes coming from the master cylinder. The remaining four are for the chassis brake tubes going to each brake assembly. CAUTION: Before removing the brake tubes from the junction block, the junction block and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the brake hydraulic system. (4) Remove the four chassis brake tubes from the top of the junction block (Fig. 53). OPERATION - NON-ABS JUNCTION BLOCK The junction block distributes the brake fluid coming from the master cylinder primary and secondary ports to the four chassis brake tubes leading to the brakes at each wheel. Since the junction block mounts in the same location as the ABS integrated control unit (ICU), it allows for the common use of brake tubes going to the brakes whether the vehicle is equipped with or without ABS. NOTE: Although the brake tubes coming from the master cylinder to the junction block or ABS ICU may appear to be the same, they are not. They are unique to each brake system application. REMOVAL - NON-ABS JUNCTION BLOCK (1) Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the junction block. (2) Disconnect the battery negative cable. (3) If the vehicle is equipped with speed control, perform the following: (a) Disconnect the battery positive cable. (b) Remove the battery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL). Fig. 53 NON-ABS JUNCTION BLOCK 1 2 3 4 - MASTER CYLINDER JUNCTION BLOCK SUSPENSION CROSSMEMBER MOUNTING BOLTS (5) Remove the primary and secondary brake tubes from the top of the junction block. (6) Remove the bolts attaching the junction block mounting bracket to the front suspension crossmember (Fig. 53), then remove the junction block. INSTALLATION - NON-ABS JUNCTION BLOCK (1) Install the junction block and mounting bracket on the front suspension crossmember (Fig. 53). Install the mounting bolts and tighten to a torque of 28 N·m (250 in. lbs.). (2) Install the primary and secondary brake tubes from the master cylinder in their ports. Tighten tube nuts to a torque of 17 N·m (145 in. lbs.). Take care not to twist tubes when tightening tube nuts. They must be properly positioned to allow free movement with rubber isolated suspension crossmember. BRAKES - BASE RS 5 - 37 JUNCTION BLOCK (Continued) (3) Install the four chassis brake tubes into the outlet ports of the junction block. Tighten all 6 tube nuts to a torque of 17 N·m (145 in. lbs.). (4) If the vehicle is equipped with speed control, perform the following: (a) Install the speed control servo with its mounting nuts. (b) Connect the wiring harness to the speed control servo. (c) Install the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - INSTALLATION). (d) Install the screw securing the coolant filler neck to the battery tray. (e) Reconnect the vacuum hose connector at the tank built into the battery tray. (f) Install the battery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION). (g) Install the battery shield. (5) Remove the brake pedal holder. (6) Connect negative cable back on negative post of the battery. (7) Bleed the brake system thoroughly to ensure that all air has been expelled from the hydraulic system. (Refer to 5 - BRAKES - STANDARD PROCEDURE). (8) Road test the vehicle to verify proper operation of the brake system. Fig. 54 Master Cylinder And Booster Location 1 - MASTER CYLINDER 2 - POWER BRAKE BOOSTER BRAKE SYSTEM MASTER CYLINDER BORE/TYPE Disc/Drum - ABS 23.8 mm (15/16 in.) Conventional Compensating Port Disc/Drum - Non-ABS 23.8 mm (15/16 in.) Conventional Compensating Port MASTER CYLINDER Disc/Disc - ABS 27.0 mm (1-1/16 in.) Conventional Compensating Port DESCRIPTION Disc/Disc ABS With Traction Control DESCRIPTION The master cylinder is located on the power brake booster in the engine compartment on the driver’s side (Fig. 54). This vehicle uses 3 different master cylinders. Master cylinder usage depends on what type of brake system the vehicle is equipped with. CAUTION: Master cylinders are not interchangeable between systems. Performance and stopping distance issues will result if the incorrect master cylinder is installed on the vehicle. For information on master cylinder application, bore and type, view the following table: 27.0 mm (1-1/16 in.) Dual Center Port CAUTION: When replacing a master cylinder, be sure to use the correct master cylinder for the type of brake system the vehicle is equipped with. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and threaded ports with seats for the hydraulic brake line connections. The brake fluid reservoir is mounted on the top of the master cylinder. It is made of a see-through polypropylene type plastic for easy fluid level viewing. A brake fluid level switch is attached to the brake fluid reservoir. The master cylinder is not a repairable component and must be replaced if diagnosed to be functioning improperly. The brake fluid reservoir and brake fluid level switch can be replaced separately. 5 - 38 BRAKES - BASE RS MASTER CYLINDER (Continued) CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface from the bore. DESCRIPTION - RHD The master cylinder used on right hand drive (RHD) vehicles functions similarly to that used on left hand drive (LHD) vehicles. The RHD master cylinder, as well as the RHD power brake booster, is located in the same area, but lower in the engine compartment than LHD models (Fig. 55). For that reason an extension manifold is placed between the fluid reservoir and master cylinder housing allowing the fluid reservoir to be positioned in the same location as on LHD models. (1) Clamp master cylinder in a vise. NOTE: Use correct bleeder tubes when bleeding master cylinder. Master cylinder outlet ports vary in size and type depending on whether master cylinder is for a vehicle equipped with traction control or not. Traction control equipped master cylinders require the additional use of ISO style flare adapters supplied in Special Tool Package 8822 to be used in conjunction with Bleeder Tubes, Special Tool Package 8358. (2) Attach special tools for bleeding master cylinder in the following fashion: (a) For non-traction control equipped master cylinders, thread a Bleeder Tube, Special Tool 8358–1, into each outlet port. Tighten each tube to 17 N·m (145 in. lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 56). (b) For traction control equipped master cylinders, thread one Adapter, Special Tool 8822–2, in each outlet port. Tighten Adapters to 17 N·m (145 in. lbs.) torque. Next, thread a Bleeder Tube, Special Tool 8358–1, into each Adapter. Tighten each tube to 17 N·m (145 in. lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 56). Fig. 55 RHD MASTER CYLINDER AND POWER BRAKE BOOSTER 1 2 3 4 - POWER BRAKE BOOSTER BRAKE FLUID LEVEL SWITCH FLUID RESERVOIR MASTER CYLINDER OPERATION When the brake pedal is depressed, the master cylinder primary and secondary pistons apply brake pressure through the chassis tubes to the brakes at each tire and wheel assembly. The master cylinder primary outlet port supplies hydraulic pressure to the right front and left rear brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes. Fig. 56 Master Cylinder Set Up For Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting flange. Do not clamp master cylinder piston rod, reservoir, seal or body. 1 - BLEEDER TUBES 8358 2 - WOODEN DOWEL 3 - ADAPTER 8822-2 (USE ONLY ON TRACTION CONTROL EQUIPPED MASTER CYLINDERS) 4 - ADAPTER 8822-2 (USE ONLY ON TRACTION CONTROL EQUIPPED MASTER CYLINDERS) BRAKES - BASE RS 5 - 39 MASTER CYLINDER (Continued) NOTE: Make sure open ends of bleeder tubes stay below surface of brake fluid once reservoir is filled to proper level. (3) Fill brake fluid reservoir with Mopart brake fluid or equivalent conforming to DOT 3 (DOT 4 and DOT 4+ are acceptable) specifications. Make sure fluid level is above tips of bleeder tubes in reservoir to ensure no air is ingested during bleeding. (4) Using a wooden dowel as a pushrod (Fig. 56), slowly depress master cylinder pistons, then release pressure, allowing pistons to return to released position. Repeat several times until all air bubbles are expelled. Make sure fluid level stays above tips of bleeder tubes in reservoir while bleeding. (5) Remove bleeder tubes from master cylinder outlet ports, then plug outlet ports and install fill cap on reservoir. (6) Remove master cylinder from vise. (7) Install master cylinder on vehicle. (Refer to 5 BRAKES - BASE/HYDRAULIC/MECHANICAL/MASTER CYLINDER - INSTALLATION) REMOVAL REMOVAL - LHD CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent the power brake booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle’s engine not running, until a firm feeling brake pedal is achieved. (1) With engine not running, pump brake pedal until a firm pedal is achieved (4-5 strokes). (2) Disconnect negative battery terminal. (3) Disconnect positive battery terminal. (4) Remove battery shield. (5) Remove nut and clamp securing battery to tray, remove battery. (6) Thoroughly clean all surfaces of the brake fluid reservoir and master cylinder. Use only solvent such as Mopart Brake Parts Cleaner or equivalent. (7) Remove wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir (Fig. 57). (8) Disconnect primary and secondary brake tubes from master cylinder housing (Fig. 57). Install sealing plugs in the now open brake tube outlet ports. CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly Fig. 57 MASTER CYLINDER AND BOOSTER 1 2 3 4 5 6 - POWER BRAKE BOOSTER BOOSTER IDENTIFICATION LABEL FLUID LEVEL SWITCH CONNECTOR PRIMARY BRAKE TUBE NUT SECONDARY BRAKE TUBE NUT MASTER CYLINDER cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. (9) Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopart Brake Parts Cleaner or equivalent. (10) Remove two nuts attaching master cylinder to power brake booster (Fig. 58). Fig. 58 MASTER CYLINDER MOUNTING 1 2 3 4 - MASTER CYLINDER MOUNTING NUTS MASTER CYLINDER SECONDARY TUBE NUT AT ICU PRIMARY TUBE NUT AT ICU (11) Slide master cylinder straight out of power brake booster. 5 - 40 BRAKES - BASE RS MASTER CYLINDER (Continued) CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. (12) Remove vacuum seal located on the mounting flange of the master cylinder. The vacuum seal is removed from master cylinder by carefully pulling it off the rear of master cylinder. Do not attempt to pry the seal off the master cylinder by inserting a sharp tool between seal and master cylinder casting. REMOVAL - RHD CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent the power brake booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle’s engine not running, until a firm feeling brake pedal is achieved. (1) With engine not running, pump brake pedal until a firm pedal is achieved (4 or 5 strokes). (2) Disconnect negative battery terminal. (3) Disconnect positive battery terminal. (4) Remove battery shield. (5) Remove nut and clamp securing battery to tray, remove battery. (6) Thoroughly clean all surfaces of the brake fluid reservoir and master cylinder. Use only solvent such as Mopart Brake Parts Cleaner or equivalent. (7) Remove wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir (Fig. 55). (8) Disconnect primary and secondary brake tubes from master cylinder housing (Fig. 59). Install sealing plugs in the now open brake tube outlet ports. CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. (9) Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopart Brake Parts Cleaner or equivalent. (10) Remove two nuts attaching master cylinder to power brake booster (Fig. 59). (11) Slide master cylinder straight out of power brake booster. Fig. 59 RHD MASTER CYLINDER MOUNTING 1 - PRIMARY BRAKE TUBE NUT 2 - SECONDARY BRAKE TUBE NUT 3 - MASTER CYLINDER MOUNTING NUTS CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. (12) Remove vacuum seal located on the mounting flange of the master cylinder. The vacuum seal is removed from master cylinder by carefully pulling it off the rear of master cylinder. Do not attempt to pry the seal off the master cylinder by inserting a sharp tool between seal and master cylinder casting. DISASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) (1) Clean master cylinder housing and brake fluid reservoir. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. (2) Remove brake fluid reservoir cap. Using a syringe or equivalent type tool empty as much brake fluid as possible from the reservoir. CAUTION: When removing fluid reservoir from the master cylinder, do not pry off using any type of tool. This can damage the fluid reservoir or master cylinder housing. (3) Remove the master cylinder assembly from the power brake vacuum booster. (Refer to 5 - BRAKES BASE/HYDRAULIC/MECHANICAL/MASTER CYLINDER - REMOVAL). (4) Mount the master cylinder in a vise using the master cylinder mounting flange. BRAKES - BASE RS 5 - 41 MASTER CYLINDER (Continued) (5) Using correct size pin punch, remove the two retaining pins between the fluid reservoir and master cylinder housing (Fig. 60). (2) Lubricate reservoir mounting area with fresh clean brake fluid. Place reservoir in position over sealing grommets. Seat reservoir into sealing grommets using a rocking motion while firmly pressing down on fluid reservoir. (3) Be sure fluid reservoir is positioned properly on master cylinder. Bottom of fluid reservoir is to be touching the top of both sealing grommets when properly installed on master cylinder housing. (4) Install the two fluid reservoir to master cylinder retaining pins (Fig. 60). (5) Install the master cylinder assembly on the power brake booster. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLINDER INSTALLATION) (6) Fill fluid reservoir to its proper level as indicated on the side of the fluid reservoir. Fig. 60 Fluid Reservoir Retaining Pins (Typical) 1 - FLUID RESERVOIR 2 - RETAINING PINS 3 - MASTER CYLINDER (6) Rock the brake fluid reservoir from side to side while pulling up to remove it from the seal grommets in master cylinder housing. (7) Remove the two master cylinder housing to brake fluid reservoir seal grommets (Fig. 61). INSTALLATION INSTALLATION - LHD CAUTION: Different types of master cylinders are used on this vehicle depending on brake options. If a new master cylinder is being installed, be sure it is the correct master cylinder for the type of brake system the vehicle is equipped with. CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be installed on the master cylinder. (1) Install a NEW vacuum seal on master cylinder making sure seal fits squarely in groove of master cylinder casting. (2) Position master cylinder on studs of power brake booster, aligning booster push rod with master cylinder piston. (3) Install the two master cylinder mounting nuts (Fig. 58). Tighten both mounting nuts to a torque of 25 N·m (225 in. lbs.). Fig. 61 Master Cylinder To Fluid Reservoir Seal Grommets 1 - SEAL GROMMETS 2 - MASTER CYLINDER ASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) (1) Install new master cylinder housing to brake fluid reservoir sealing grommets in master cylinder housing (Fig. 61). CAUTION: When tightening the primary and secondary brake tube nuts at master cylinder, be sure brake tubes do not contact any other components within the vehicle and that there is slack in the flexible sections of the tubes. This is required due to the movement between the ABS ICU and the master cylinder while the vehicle is in motion. (4) Connect primary and secondary brake tubes to master cylinder primary and secondary ports (Fig. 57). Brake tubes must be held securely when tightened to control orientation of flex section. Tighten tube nuts to a torque of 17 N·m (145 in. lbs.). 5 - 42 BRAKES - BASE RS MASTER CYLINDER (Continued) (5) Install wiring harness connector to brake fluid level switch mounted in brake fluid reservoir (Fig. 57). (6) Install battery, clamp and nut. (7) Install battery shield. (8) Connect positive battery terminal. (9) Connect negative battery terminal. (10) Fill master cylinder with clean, fresh Mopart Brake Fluid or equivalent. (11) Road test vehicle to ensure proper operation of brakes. INSTALLATION - RHD CAUTION: Different types of master cylinders are used on this vehicle depending on brake options. If a new master cylinder is being installed, be sure it is the correct master cylinder for the type of brake system the vehicle is equipped with. CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be installed on the master cylinder. (1) Install a NEW vacuum seal on master cylinder making sure seal fits squarely in groove of master cylinder casting. (2) Position master cylinder on studs of power brake booster, aligning booster push rod with master cylinder piston. (3) Install the two master cylinder mounting nuts (Fig. 59). Tighten both mounting nuts to a torque of 25 N·m (225 in. lbs.). CAUTION: When tightening the primary and secondary brake tube nuts at master cylinder, be sure brake tubes do not contact any other components within the vehicle and that there is slack in the flexible sections of the tubes. This is required due to the movement between the ABS ICU and the master cylinder while the vehicle is in motion. (4) Connect primary and secondary brake tubes to master cylinder primary and secondary ports (Fig. 59). Brake tubes must be held securely when tightened to control orientation of flex section. Tighten tube nuts to a torque of 17 N·m (145 in. lbs.). (5) Install wiring harness connector to brake fluid level switch mounted in brake fluid reservoir (Fig. 55). (6) Install battery, clamp and nut. (7) Install battery shield. (8) Connect positive battery terminal. (9) Connect negative battery terminal. (10) Fill master cylinder with clean, fresh Mopart Brake Fluid or equivalent. (11) Road test vehicle to ensure proper operation of brakes. PEDAL - ADJUSTABLE DESCRIPTION The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The effort required for pedal application will not change regardless of pedal position. The adjustable pedal system allows the pedals to adjust up to 3 inches (75 mm) at a rate of approximately 0.4 in./sec. (9 mm/sec.). An adjustment switch is located on the left side of the steering column lower shroud. If the vehicle is equipped with Remote Keyless Entry (RKE), an optional memory feature is available. The serviceable components of the APS are: • Adjustable pedal assembly (includes motor, cables, pedals, gear box, sensor and module) • Adjustable pedal module (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/ ADJUSTABLE PEDAL MODULE) • Adjustable pedal switch • Pedal position sensor OPERATION Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor. The pedal drive motor turns a screw that changes the position of the accelerator pedal. The motor also drives a cable connected to a gear box that changes the brake pedal position the same distance as the accelerator pedal. The pedals can be moved rearward (closer to the driver) or forward (away from driver). Each pedal is moved on its activating lever to a position where the driver feels most comfortable. The position and operation of the activating levers are not changed. Pedal adjustment is inhibited when the vehicle is in reverse or when cruise control is engaged. The Electronic Vehicle Information Center (EVIC) will display a message when the Adjustable Pedal Module (APM) is disabled. i.e.: 9Adjustable Pedal Disabled Cruise Control Engaged9 or 9Adjustable Pedal Disabled - Vehicle in Reverse9. Foot pressure or debris can stall pedal adjustment. In order to avoid damage to system components dur- BRAKES - BASE RS 5 - 43 PEDAL - ADJUSTABLE (Continued) ing pedal adjustment, the APM will monitor pedal position sensor voltage. If the APM does not detect expected voltage change within 3 seconds, it will cut power to the adjustable pedal motor. An optional memory feature is available. This allows storing of one or two preferred pedal positions in the APS. A preferred position can be stored and recalled using the door-mounted switches. A stored pedal position can be recalled (but not stored) using the Remote Keyless Entry (RKE) if equipped with the memory feature. (4) Disconnect parking brake release link at release handle. (5) Compress tabs on sides of data link diagnostic connector and remove it from knee blocker reinforcement plate. (6) Remove screws securing knee blocker reinforcement plate in place, then remove reinforcement plate (Fig. 62). (7) Remove screws securing instrument panel lower left reinforcement in place, then remove reinforcement (Fig. 63). DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL SYSTEM Refer to Appropriate Diagnostic Information. REMOVAL NOTE: Before proceeding, review all Steering Column and Airbag Warnings and Cautions. (Refer to 19 - STEERING/COLUMN - WARNING)(Refer to 8 ELECTRICAL/RESTRAINTS - WARNING) (1) Remove battery ground cable terminal from battery negative post and isolate. (2) Under instrument panel, remove silencer panel below lower steering column cover. (3) Remove screws securing lower steering column cover/knee blocker, then remove it (Fig. 62). Fig. 63 Instrument Panel Lower Left Reinforcement 1 - INSTRUMENT PANEL LOWER REINFORCEMENT 2 - STEERING WHEEL 3 - LOWER LEFT REINFORCEMENT Fig. 62 Lower Steering Column Cover And Reinforcement 1 - INSTRUMENT PANEL 2 - REINFORCEMENT PLATE 3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER (8) Remove brake lamp switch. Discard the original switch; it must not be reused (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL) (9) Remove screws fastening upper and lower steering column shrouds to steering column (Fig. 64). (10) Remove the lower shroud with adjustable pedal switch; disconnect switch wiring connector along left side of column as shroud is removed (Fig. 65). (11) Disconnect traction control off switch wiring connector; Remove upper shroud with traction control off switch. (12) Disconnect wiring harness connectors (as equipped) from clockspring, multi-function switch, halo lamp, SKIM module, ignition switch and BTSI solenoid (Fig. 65). (13) Disconnect column wiring harness routing clip from column. 5 - 44 BRAKES - BASE RS PEDAL - ADJUSTABLE (Continued) Fig. 64 Steering Column Shrouds 1 2 3 4 5 - FIXED SHROUD UPPER SHROUD CLOCKSPRING LOWER SHROUD STEERING COLUMN Fig. 66 Shift Cable At Steering Column 1 2 3 4 5 - SHIFT LEVER MECHANISM SHIFT CABLE BRACKET PRNDL CABLE STEERING COLUMN (16) Remove pinch side clip, then remove shift cable from bracket on column. (17) Turn the steering wheel from the STRAIGHTAHEAD position 180° to the right (upside-down position), then remove the key and lock the column in place. (18) Remove the pinch bolt securing column coupling to intermediate shaft (Fig. 67). Fig. 65 Pedal Switch Wiring Connector 1 2 3 4 - STEERING COLUMN FIXED SHROUD BRAKE TRANSMISSION SHIFT INTERLOCK B.T.S.I. WIRING CONNECTOR PEDAL SWITCH WIRING CONNECTOR (14) Disconnect PRNDL cable from shift lever and column bracket (Fig. 66). (15) Disconnect shift cable at shift lever mechanism pin (Fig. 66). Fig. 67 Pinch Bolt 1 - PINCH BOLT 2 - STEERING COLUMN BRAKES - BASE RS 5 - 45 PEDAL - ADJUSTABLE (Continued) (19) Loosen two lower column mounting nuts. (20) Remove two upper column mounting nuts. (21) Remove the steering column. (22) Remove dash seal silencer shell over steering column intermediate shaft (Fig. 68). Fig. 68 Intermediate Shaft Dash Seal And Silencer Shell 1 - INTERMEDIATE SHAFT 2 - DASH SEAL 3 - SILENCER SHELL (23) Remove two nuts securing brake lamp switch bracket to pedal assembly (Fig. 69). Remove bracket. (24) Disconnect pedal wiring harness connector (Fig. 69). (25) Remove pedal wiring harness from clips along pedal bracket. (26) Position a small screwdriver between the center tang on the power brake booster input rod-tobrake pedal pin retaining clip (Fig. 70). Fig. 70 Input Rod Brake Pedal Retaining Clip Removal 1 2 3 4 5 - BRAKE PEDAL INPUT ROD SCREWDRIVER RETAINING CLIP BRAKE PEDAL PIN (27) Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when assembling. (28) Slide booster input rod off pedal pin. (29) Remove the four nuts attaching power brake booster to dash panel (Fig. 71). (30) Remove two brake pedal upper mounting bolts at instrument panel dash bracket (Fig. 71). (31) Disconnect accelerator cable retainer at accelerator pedal; remove cable from pedal. (32) Remove adjustable brake pedal assembly. INSTALLATION Fig. 69 Brake Lamp Switch Bracket 1 2 3 4 - BRAKE LAMP SWITCH BRACKET PEDAL WIRING HARNESS CONNECTOR STEERING COLUMN INTERMEDIATE SHAFT BRACKET MOUNTING NUTS (1) Install adjustable brake pedal assembly under instrument panel. (2) Install two brake pedal upper mounting bolts at instrument panel dash bracket (Fig. 71). Do not fully tighten at this time. (3) Install four nuts attaching power brake booster to dash panel (Fig. 71). 5 - 46 BRAKES - BASE RS PEDAL - ADJUSTABLE (Continued) Fig. 71 Booster Mounting (Typical) 1 - DASH BRACKET 2 - POWER BRAKE BOOSTER 3 - BRAKE PEDAL ASSEMBLY (4) Tighten four booster mounting nuts and two pedal bracket upper mounting bolts to 28 N·m (21 ft. lbs.) torque. (5) Install accelerator cable to pedal; install cable retainer at accelerator pedal. (6) Install booster input rod on brake pedal pin and install a NEW retaining clip (Fig. 72). (9) Install dash seal silencer shell over steering column intermediate shaft and fasten in place (Fig. 68). (10) Install the steering column on the mounting studs. Install the two upper and two lower mounting nuts. Tighten the upper, then lower mounting nuts to 12 N·m (105 in. lbs.) torque. (11) Install the column shaft coupling onto the intermediate shaft and install the pinch bolt (steering column should still be locked position it was placed in during removal). Make sure the rounded side of the intermediate shaft is matched to the curvature of the coupling. Tighten the pinch bolt to 28 N·m (250 in. lbs.). (12) Attach shift cable housing to bracket on column. (13) Connect shift cable end to shift lever mechanism pin (Fig. 66). (14) Connect PRNDL cable to end of shift lever mechanism pin and column bracket (Fig. 66). (15) Connect column wiring harness connectors to SKIM (if equipped), BTSI solenoid, ignition switch, halo lamp, multi-function switch, and clockspring. (16) Install the upper shroud (Refer to 19 STEERING/COLUMN/LOWER SHROUD - INSTALLATION). (17) If equipped, connect traction control off switch wiring connector. (18) Install upper shroud (with traction control off switch if equipped) (Fig. 64). (19) Connect adjustable pedal switch wiring connector along left side of column (Fig. 65). (20) Install the lower shroud with adjustable pedal switch. Install screws fastening steering column shrouds to steering column (Fig. 64). CAUTION: Do not reuse the original brake 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. Fig. 72 Retaining Pin Installed On Brake Pedal Pin 1 - BRAKE PEDAL 2 - RETAINING CLIP 3 - BOOSTER INPUT ROD (7) Install wiring harness in clips along pedal bracket, then connect harness to pedal wiring harness connector (Fig. 69). (8) Install brake lamp switch bracket on pedal assembly (Fig. 69). Tighten mounting nuts to 6 N·m (50 in. lbs.) torque. (21) Install and adjust NEW brake lamp switch. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING EXTERIOR/BRAKE LAMP SWITCH - INSTALLATION) (22) Install instrument panel lower left reinforcement (Fig. 63). (23) Attach hood release to lower left reinforcement. (24) Install knee blocker reinforcement plate (Fig. 62). (25) Connect parking brake release link to release handle. (26) Install data link diagnostic connector to mounting hole in reinforcement plate. BRAKES - BASE RS 5 - 47 PEDAL - ADJUSTABLE (Continued) (27) Install lower steering column cover/knee blocker (Fig. 62). (28) Install silencer panel below lower steering column cover/knee blocker. NOTE: When reconnecting the battery on a vehicle that has had the airbag module removed, the following procedure should be used. (29) Reconnect ground cable to negative post of battery in following manor: (a) Connect scan tool (DRBIIIt) to data link diagnostic connector located below steering column. (b) Turn ignition key to ON position. Exit vehicle with scan tool leaving scan tool harness plugged in. (c) Ensuring that there are no occupants in vehicle, connect ground (-) cable to the negative post of the battery. (d) Using scan tool, read and record any airbag fault codes. Refer to Appropriate Diagnostic Information if any faults are found. (e) Through drivers open window, Reach around back of steering wheel (between steering wheel and instrument cluster) and turn ignition key to OFF, then back ON while observing instrument cluster airbag indicator lamp. It should go on for six to eight seconds, then go out. This action indicates that airbag system is functioning normally. If airbag indicator lamp fails to light, blinks on and off, or goes on and stays on, there is an airbag system malfunction. Refer to Appropriate Diagnostic Information to diagnose the system malfunction. (30) Using scan tool (DRBIIIt), check for and clear any existing adjustable pedal fault codes. The adjustable pedal system is now activated. (31) Turn key to OFF and remove scan tool from vehicle. (32) Test operation of adjustable pedals, memory seats (if equipped), RKE (if equipped), and all functions that are steering column operated. If applicable, reset the radio and the clock. (33) Road test the vehicle to ensure proper operation of the steering and brake systems. PEDAL TORQUE SHAFT - RHD REMOVAL (1) Remove the instrument panel. (Refer to 23 BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL) (2) Remove the HVAC housing. (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING - REMOVAL) (3) Remove the retaining clip at the torque shaft end of the brake pedal-to-torque shaft link. Remove the link from the torque shaft. Discard the retaining clip. It is not to be reused. Replace with a new clip when reassembled. (4) Locate the booster input rod-to-brake pedal torque shaft connection and remove the retaining clip (Fig. 73). Discard the retaining clip. It is not to be reused. Replace with a new clip when reassembled. Fig. 73 POWER BRAKE BOOSTER BRACKET 1 2 3 4 - BOOSTER BRACKET PEDAL TORQUE SHAFT RETAINING CLIP BOOSTER MOUNTING NUTS (5) Remove the four (4) brake booster retaining nuts from inside the passenger compartment (Fig. 74). (6) Remove the retaining nut from the brake booster bracket located above the booster in the engine compartment (Fig. 74). (7) Remove the power brake booster bracket. (8) Rotate the pedal torque shaft and remove it out the left side of the vehicle. INSTALLATION (1) Lubricate both ends of the torque shaft with MS-4517 Lubricant or equivalent and install the torque shaft from the left side reversing the removal procedure. (2) Install the brake booster bracket on the left end of the shaft. (3) Install the four brake booster retaining nuts inside the passenger compartment. Tighten the mounting nuts to a torque of 29 N·m (250 in. lbs.). (4) Install the retaining nut for the brake booster bracket in the engine compartment. Tighten the mounting nuts to a torque of 29 N·m (250 in. lbs.). (5) Using lubriplate, or equivalent, coat the surface of the brake pedal torque shaft pin where it contacts the booster input rod. Also coat the surface of 5 - 48 BRAKES - BASE RS PEDAL TORQUE SHAFT - RHD (Continued) CAUTION: Do not reuse the original brake 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. (10) Remove and replace the brake lamp switch with a NEW switch. (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - INSTALLATION) (11) Road test vehicle to ensure proper operation of the brakes. POWER BRAKE BOOSTER DESCRIPTION Fig. 74 BOOSTER, TORQUE SHAFT AND PEDAL MOUNTING 1 2 3 4 5 6 7 8 - PEDAL MOUNTING NUT BRAKE PEDAL ASSEMBLY PEDAL MOUNTING NUT PEDAL TORQUE SHAFT BOOSTER MOUNTING NUT BOOSTER BRACKET POWER BRAKE BOOSTER BOOSTER BRACKET MOUNTING NUT The power brake booster mounts on the engine compartment side of the dash panel. It is connected to the brake pedal by the input (push) rod (Fig. 75). The master cylinder is bolted to the front of the booster. A vacuum line connects the power brake booster to the intake manifold. the brake pedal torque shaft pin where it contacts the brake pedal link. CAUTION: When installing the power brake booster input rod on the brake pedal torque shaft pin, do not reuse the old retaining clip. (6) Install booster input rod on brake pedal torque shaft pin and install a NEW retaining clip (Fig. 73). CAUTION: When installing the brake pedal link on the brake pedal torque shaft pin, do not reuse the old retaining clip. (7) Connect the brake pedal link to the torque shaft. Install a NEW retaining clip at the torque shaft end of the brake pedal-to-torque shaft link. (8) Install the HVAC housing. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HVAC HOUSING - INSTALLATION) (9) Install the instrument panel. (Refer to 23 BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION) Fig. 75 Power Brake Booster (Typical) 1 - VACUUM CHECK VALVE 2 - POWER BRAKE BOOSTER ASSEMBLY 3 - INPUT ROD 4 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING STUDS (4) 5 - MASTER CYLINDER MOUNTING STUDS (2) 6 - OUTPUT ROD BRAKES - BASE RS 5 - 49 POWER BRAKE BOOSTER (Continued) All vehicles use a 270 mm single diaphragm vacuum power brake booster. Vehicles equipped with Disc/Disc brakes use a different power brake booster than vehicles equipped with Disc/Drum brakes. Differences between the two are internal. Service is the same for all boosters. The power brake booster can be identified by the tag attached to the body of the booster (Fig. 76). This tag contains the production part number, the date it was built, and who the manufacturer of the power brake booster is. NOTE: The power brake booster assembly is not a repairable component and must be replaced as a complete assembly if found to be faulty in any way. The check valve located on the power brake booster face is not repairable, but it can be replaced separately from the power brake booster. Fig. 76 MASTER CYLINDER AND BOOSTER 1 2 3 4 5 6 - POWER BRAKE BOOSTER BOOSTER IDENTIFICATION LABEL FLUID LEVEL SWITCH CONNECTOR PRIMARY BRAKE TUBE NUT SECONDARY BRAKE TUBE NUT MASTER CYLINDER The different engine combinations used in this vehicle require different vacuum hose routings to the power brake booster. All vacuum hoses must be routed from the engine to the power brake booster without kinks or excessively tight bends. As the brake pedal is depressed, the power brake booster’s input rod moves forward (Fig. 75). This opens and closes valves in the power booster allowing atmospheric pressure to enter on one side of a diaphragm. Engine vacuum is always present on the other side. This difference in pressure forces the output rod of the power brake booster out against the primary piston of the master cylinder. As the pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system. DIAGNOSIS AND TESTING - 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. 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 on the vacuum check valve, then place a vacuum gauge in line between the vacuum hose and the valve. (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 Hg, the hose or check valve to the booster has a restriction or leak. Once an adequate vacuum supply is obtained, repeat the BASIC TEST. OPERATION The power brake booster reduces the amount of force required by the driver to obtain the necessary hydraulic pressure to stop a vehicle. The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on the engine through a vacuum hose and the power brake booster check valve (Fig. 75). VACUUM LEAK TEST (1) Disconnect the vacuum hose on the vacuum check valve, then place a vacuum gauge in line between the vacuum hose and the valve. (2) Start the engine. (3) Allow the engine to warm up to normal operating temperature and engine idle. 5 - 50 BRAKES - BASE RS POWER BRAKE BOOSTER (Continued) (4) Using vacuum line pliers, close off the vacuum supply hose near the booster, but before the vacuum gauge, then 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. 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 vacuum line 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. (9) Remove the pliers and vacuum gauge. (a) Disconnect wiring harness connector from the speed control servo. (b) Remove the two servo mounting nuts. (c) Lay speed control servo off to the side, out of the way. (10) Remove the wiper module (unit). (Refer to 8 ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL) (11) Disconnect wiring harness connector from brake fluid level switch in master cylinder fluid reservoir (Fig. 77). REMOVAL REMOVAL - LHD CAUTION: Reserve vacuum in power brake booster must be pumped down (removed) before removing master cylinder from booster. This is necessary to prevent booster from sucking in any contamination as master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle’s engine not running, until a firm feeling brake pedal is achieved. (1) With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). (2) Remove negative battery cable terminal from battery. (3) Remove positive battery cable terminal from battery. (4) Remove battery thermal guard shield. (5) Remove battery clamp, nut and battery from the battery tray. (6) Remove screw securing engine coolant filler tube to battery tray. (7) If the vehicle is equipped with speed control, disconnect the vacuum hose at the vacuum tank built into the battery tray. (8) Remove the two nuts and one bolt securing battery tray in place. Remove battery tray. (9) If vehicle is equipped with speed control: Fig. 77 Master Cylinder And Booster 1 2 3 4 5 6 - POWER BRAKE BOOSTER BOOSTER IDENTIFICATION LABEL FLUID LEVEL SWITCH CONNECTOR PRIMARY BRAKE TUBE NUT SECONDARY BRAKE TUBE NUT MASTER CYLINDER CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. (12) Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopart Brake Parts Cleaner or equivalent. (13) Disconnect primary and secondary brake tubes from ABS integrated control unit or non-ABS junction block (Fig. 78). Install sealing plugs in the now open brake tube ports and install caps on ends of tubes. NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the master cylinder from the vacuum booster. (14) Remove two nuts attaching master cylinder to power brake booster (Fig. 78). BRAKES - BASE RS 5 - 51 POWER BRAKE BOOSTER (Continued) Fig. 78 Master Cylinder Mounting 1 2 3 4 - MASTER CYLINDER MOUNTING NUTS MASTER CYLINDER SECONDARY TUBE NUT AT ICU PRIMARY TUBE NUT AT ICU Fig. 79 Vacuum Booster Input Rod Retaining Pin 1 2 3 4 5 - BRAKE PEDAL INPUT ROD SCREWDRIVER RETAINING CLIP BRAKE PEDAL PIN (15) Slide master cylinder straight out of power brake booster. Remove master cylinder with primary and secondary tubes from vehicle. CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. (16) Disconnect vacuum hose from check valve located on vacuum booster. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER. (17) Inside vehicle, remove silencer panel under instrument panel below steering column. (18) Locate the booster input rod to brake pedal connection under the instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip (Fig. 79). (19) Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when assembling. (20) Slide booster input rod off pedal pin. (21) Remove the four nuts attaching power brake booster to dash panel (Fig. 80). (22) Slide power brake booster forward and remove through engine compartment (Fig. 81). Fig. 80 Booster Mounting 1 - DASH BRACKET 2 - POWER BRAKE BOOSTER 3 - BRAKE PEDAL ASSEMBLY CAUTION: Do not attempt to disassemble the power brake vacuum booster. It is serviced ONLY as a complete assembly. 5 - 52 BRAKES - BASE RS POWER BRAKE BOOSTER (Continued) Fig. 81 Booster Removal/Installation Fig. 82 RHD Master Cylinder And Power Brake Booster REMOVAL - RHD CAUTION: Reserve vacuum in power brake booster must be pumped down (removed) before removing master cylinder from booster. This is necessary to prevent booster from sucking in any contamination as master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle’s engine not running, until a firm feeling brake pedal is achieved. (1) With engine not running, pump the brake pedal until a firm pedal is achieved (4 or 5 strokes). (2) Remove negative battery cable terminal from battery. (3) Remove positive battery cable terminal from battery. (4) Remove battery thermal guard shield. (5) Remove battery clamp, nut and battery from the battery tray. (6) If the vehicle is equipped with speed control, disconnect the vacuum hose at the vacuum tank built into the battery tray. (7) Remove the two nuts and one bolt securing battery tray in place. Remove battery tray. (8) If vehicle is equipped with speed control: (a) Disconnect wiring harness connector from the speed control servo. (b) Remove the two servo mounting nuts. (c) Lay speed control servo off to the side, out of the way. (9) If the vehicle is equipped with the 2.5L diesel engine, remove the coolant recovery pressure container and bracket. (Refer to 7 - COOLING/ENGINE/ COOLANT RECOVERY PRESS CONTAINER REMOVAL) (10) Disconnect wiring harness connector from brake fluid level switch in master cylinder fluid reservoir (Fig. 82). 1 2 3 4 - POWER BRAKE BOOSTER BRAKE FLUID LEVEL SWITCH FLUID RESERVOIR MASTER CYLINDER CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. (11) Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopart Brake Parts Cleaner or equivalent. NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the master cylinder from the booster. (12) Remove two nuts attaching master cylinder to power brake booster (Fig. 83). (13) Slide master cylinder straight out of power brake booster. Lay master cylinder with primary and secondary tubes to the side, out of the way. CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. (14) Disconnect vacuum hose from check valve located on booster. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER. (15) Under the instrument panel, remove booster input rod trim cover. (16) Locate the booster input rod to brake pedal torque shaft connection under the instrument panel. BRAKES - BASE RS 5 - 53 POWER BRAKE BOOSTER (Continued) (19) Remove the three easily accessed mounting nuts attaching power brake booster to dash panel and loosen fourth (Fig. 85). As fourth nut is loosened, push the booster forward periodically until the nut can be completely removed. Fig. 83 RHD Master Cylinder Mounting 1 - PRIMARY BRAKE TUBE NUT 2 - SECONDARY BRAKE TUBE NUT 3 - MASTER CYLINDER MOUNTING NUTS Position a small screwdriver between the center tang on the retaining clip (Fig. 84). Fig. 85 Booster, Torque Shaft And Pedal Mounting 1 2 3 4 5 6 7 8 - PEDAL MOUNTING NUT BRAKE PEDAL ASSEMBLY PEDAL MOUNTING NUT PEDAL TORQUE SHAFT BOOSTER MOUNTING NUT BOOSTER BRACKET POWER BRAKE BOOSTER BOOSTER BRACKET MOUNTING NUT (20) Slide power brake booster forward and remove through engine compartment (Fig. 86). Fig. 84 Booster Input Rod Pin Retaining Clip (Typical) 1 2 3 4 5 - BRAKE PEDAL INPUT ROD SCREWDRIVER RETAINING CLIP BRAKE PEDAL PIN CAUTION: Do not attempt to disassemble the power brake vacuum booster. It is serviced ONLY as a complete assembly. INSTALLATION INSTALLATION - LHD (17) Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal torque shaft pin. Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when assembling. (18) Remove booster input rod from pedal torque shaft pin. (1) Position power brake booster on dash panel using the reverse procedure of its removal (Fig. 81). It may be necessary to push in on booster input rod as it is guided through the dash panel. (2) Install the four nuts mounting the booster to the dash panel (Fig. 80). Tighten the mounting nuts to a torque of 29 N·m (250 in. lbs.). 5 - 54 BRAKES - BASE RS POWER BRAKE BOOSTER (Continued) removed for some service, a new switch must be installed and adjusted. (5) Remove and replace the brake lamp switch with a NEW switch. (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - INSTALLATION) (6) Install the silencer panel below the steering column. (7) Connect vacuum hose to check valve on power brake booster. Fig. 86 RHD Booster Removal/Installation 1 - POWER BRAKE BOOSTER 2 - MASTER CYLINDER (3) Using lubriplate, or equivalent, coat the surface of the brake pedal pin where it contacts the booster input rod. CAUTION: When installing the brake pedal pin on the power brake booster input rod, do not re-use the old retaining clip. (4) Install booster input rod on brake pedal pin and install a NEW retaining clip (Fig. 87). CAUTION: The master cylinder (and its rear seal) is used to create the seal for holding vacuum in the vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the vacuum booster. CAUTION: When removing the vacuum seal from the master cylinder do not use a sharp tool. (8) Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. (9) Install a NEW vacuum seal on rear mounting flange of the master cylinder (Fig. 88). Fig. 88 Vacuum Seal (Typical) Fig. 87 Retaining Pin Installed On Brake Pedal Pin 1 - BRAKE PEDAL 2 - RETAINING CLIP 3 - BOOSTER INPUT ROD CAUTION: Do not reuse the original brake 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 1 - MASTER CYLINDER ASSEMBLY 2 - VACUUM SEAL (10) Position master cylinder on studs of booster, aligning push rod on booster with master cylinder piston. (11) Install the two nuts mounting the master cylinder to the booster (Fig. 78). Tighten both mounting nuts to a torque of 25 N·m (225 in. lbs.). BRAKES - BASE RS 5 - 55 POWER BRAKE BOOSTER (Continued) (12) Connect wiring harness connector to brake fluid level switch in the master cylinder fluid reservoir (Fig. 77). (13) Connect primary and secondary brake tubes to ABS ICU or non-ABS junction block (Fig. 78). Tighten the tube nuts to 17 N·m (145 in lbs.). (14) Install wiper module (unit). (Refer to 8 ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - INSTALLATION) (15) If equipped with speed control, install speed control servo and connect wiring connector. Tighten the mounting nuts to a torque of 14 N·m (124 in. lbs.). (16) Install the battery tray. Install the two nuts and one bolt attaching the battery tray to the vehicle. Tighten the bolt and nuts to a torque of 14 N·m (124 in. lbs.). (17) If vehicle is equipped with speed control, connect the servo vacuum hose to the vacuum tank on the battery tray. (18) Install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner housing. Securely tighten hose clamp at air cleaner housing and throttle body. (19) Secure the engine coolant filler neck to the battery tray with its mounting screw. (20) Install the battery, clamp and mounting nut. (21) Install the positive battery cable on the battery. (22) Install the negative battery cable on the battery. (23) Install the battery thermal guard shield. (24) Bleed the base brakes as necessary. (Refer to 5 - BRAKES - STANDARD PROCEDURE) (25) Road test vehicle to ensure operation of the brakes. INSTALLATION - RHD (1) Position power brake booster on dash panel using the reverse procedure of its removal (Fig. 86). (2) Below instrument panel, first install the two upper nuts mounting the booster to the dash panel, drawing it into place, then install the two lower mounting nuts. Tighten the mounting nuts to a torque of 29 N·m (250 in. lbs.). (3) Using lubriplate, or equivalent, coat the surface of the brake pedal torque shaft pin where it contacts the booster input rod. CAUTION: When installing the brake pedal torque shaft pin on the power brake booster input rod, do not re-use the old retaining clip. (4) Install booster input rod on brake pedal torque shaft pin and install a NEW retaining clip (Fig. 89). (5) Install booster input rod trim cover. Fig. 89 Retaining Pin Installed On Brake Pedal Pin (Typical) 1 - BRAKE PEDAL 2 - RETAINING CLIP 3 - BOOSTER INPUT ROD (6) Connect vacuum hose to check valve on power brake booster. CAUTION: The master cylinder (and its rear seal) is used to create the seal for holding vacuum in the vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the vacuum booster. CAUTION: When removing the vacuum seal from the master cylinder, do not use a sharp tool. (7) Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. (8) Install a NEW vacuum seal on rear mounting flange of the master cylinder (Fig. 90). (9) Position master cylinder on studs of booster, aligning push rod on booster with master cylinder piston. (10) Install the two nuts mounting the master cylinder to the booster (Fig. 83). Tighten both mounting nuts to a torque of 25 N·m (225 in. lbs.). (11) Connect wiring harness connector to brake fluid level switch in the master cylinder fluid reservoir (Fig. 82). (12) If the vehicle is equipped with the 2.5L diesel engine, install the coolant recovery pressure container and bracket. (Refer to 7 - COOLING/ENGINE/ COOLANT RECOVERY PRESS CONTAINER INSTALLATION) (13) If equipped with speed control, install speed control servo and connect wiring connector. Tighten 5 - 56 BRAKES - BASE RS POWER BRAKE BOOSTER (Continued) PROPORTIONING VALVE DESCRIPTION - PROPORTIONING VALVE (HEIGHT SENSING) NOTE: Only vehicles without antilock brakes (ABS) have a proportioning valve. Vehicles with ABS utilize electronic brake distribution which is controlled through the ABS integrated control unit. Fig. 90 Vacuum Seal (Typical) 1 - MASTER CYLINDER ASSEMBLY 2 - VACUUM SEAL the mounting nuts to a torque of 14 N·m (124 in. lbs.). (14) Install the battery tray. Install the two nuts and one bolt attaching the battery tray to the vehicle. Tighten the bolt and nuts to a torque of 14 N·m (124 in. lbs.). (15) If vehicle is equipped with speed control, connect the servo vacuum hose to the vacuum tank on the battery tray. (16) Install the battery, clamp and mounting nut. (17) Install the positive battery cable on the battery. (18) Install the negative battery cable on the battery. (19) Install the battery thermal guard shield. Vehicles not equipped with ABS use a height sensing proportioning valve. It is mounted to the body of the vehicle above the rear axle (Fig. 91). It has an actuator lever that attaches to the rear axle and moves with the axle to help the valve sense the vehicle height. CAUTION: The height sensing proportioning valve is not adjustable. No attempt should be made to adjust it. It is replaced as a complete assembly. CAUTION: The use of after-market load leveling or load capacity increasing devices on this vehicle are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes. This inappropriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle. CAUTION: Do not reuse the original brake 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. (20) Remove and replace the brake lamp switch with a NEW switch. (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - INSTALLATION) (21) Bleed the base brakes as necessary. (Refer to 5 - BRAKES - STANDARD PROCEDURE) (22) Road test vehicle to ensure proper operation of the brakes. Fig. 91 HEIGHT SENSING PROPORTIONING VALVE 1 2 3 4 - PROPORTIONING VALVE - ACTUATOR LEVER - AXLE BRACKET - REAR AXLE RS BRAKES - BASE 5 - 57 PROPORTIONING VALVE (Continued) OPERATION - PROPORTIONING VALVE (HEIGHT SENSING) Vehicles not equipped with ABS use a height sensing proportioning valve. The height sensing proportioning valve operates similarly to a standard proportioning valve in the following way. As hydraulic pressure is applied to the valve, full input hydraulic pressure is supplied to the rear brakes up to a certain pressure point, called the split point. Beyond the split point, the proportioning valve reduces the amount of hydraulic pressure to the rear brakes according to a given ratio. Thus, on light brake applications, approximately equal hydraulic pressure will be transmitted to both the front and rear brakes. Upon heavier brake applications, the hydraulic pressure transmitted to the rear brakes will be lower than the front brakes. This will prevent premature rear wheel lockup and skid. Here is how the height sensing proportioning valve differs from a standard proportioning valve. As the height of the rear suspension changes, the height sensing portion of the proportioning valve changes the split point of the proportioning valve. When the height of the rear suspension is low, the proportioning valve interprets this as extra load and the split point of the proportioning valve is raised to a higher pressure to allow for more rear braking. When the height of the rear suspension is high, the proportioning valve interprets this as a light load and the split point of the proportioning valve is lowered to a lower pressure and rear braking is reduced. The height sensing proportioning valve regulates the pressure by sensing the load condition of the vehicle through the movement of the proportioning valve actuator lever (Fig. 91). As the position of the rear axle changes, depending on the load the vehicle is carrying, the movement is transferred to the proportioning valve. The proportioning valve adjusts the hydraulic pressure accordingly. The height sensing proportioning valve allows the brake system to maintain the optimal front to rear brake balance regardless of the vehicle load condition. Under a light load condition, hydraulic pressure to the rear brakes is minimized. As the rear load condition increases, so does the hydraulic pressure to the rear brakes. DIAGNOSIS AND TESTING - PROPORTIONING VALVE (HEIGHT SENSING) CAUTION: The use of aftermarket load leveling or load capacity increasing devices on this vehicle is prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes. This inap- propriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle. When a premature rear wheel skid is obtained on a brake application, it may be an indication that the hydraulic pressure to the rear brakes is above the specified output from the proportioning valve. This condition indicates a possible malfunction of the height sensing proportioning valve, which will require testing to verify that it is properly controlling the hydraulic pressure allowed to the rear brakes. Premature rear wheel skid may also be caused by contaminated front or rear brake linings. Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also, ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify that the brakes shoe assemblies on a vehicle being tested are either original equipment manufacturers (OEM) or original replacement brake shoe assemblies meeting the OEM lining material specification. This vehicles brake system is not balanced for aftermarket brake shoe assembly lining material. If both front and rear brakes check OK, proceed with the following test procedure for the height sensing proportioning valve. (1) Road test the vehicle to determine which rear wheel brake is exhibiting premature wheel skid. (2) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (3) Remove the chassis brake tube going to the rear brake in question at the proportioning valve. Remove the chassis brake tube coming from the junction block at the proportioning valve (Fig. 92). (4) Install the appropriate fittings from Pressure Test Fittings, Special Tool 6833, into the open ports of the proportioning valve. (5) Install the previously removed brake lines into the Pressure Test Fittings. Tighten all tube nuts to 17 N·m (145 in. lbs.). (6) Install a pressure gauge from Gauge Set, Special Tool C-4007-A into the open port on each pressure test fitting. Bleed air out of hose from pressure test fittings to pressure gauges at the pressure gauges. Then bleed air out of the brake line being tested at that rear wheel brake bleeder. NOTE: Actuator rod is a linear spring and is meant to flex by design. When rod is raised, it will have some curvature to it. (7) Remove the screw fastening the proportioning valve actuator rod bracket to the rear axle. Raise the actuator lever to the full-upward position and hold it there. 5 - 58 BRAKES - BASE RS PROPORTIONING VALVE (Continued) (8) With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000 psi) is obtained on the proportioning valve inlet gauge. Then, based on the type of brake system the vehicle is equipped with and the pressure specification shown on the following table, compare the pressure reading on the outlet gauge to the specification. If outlet pressure at the proportioning valve is not within specification when required inlet pressure is obtained, replace the proportioning valve. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/PROPORTIONING VALVE - REMOVAL) (9) Remove the pressure test fittings and pressure gauges from the proportioning valve. (10) Install the chassis brake lines in the correct ports of the proportioning valve. Tighten all tube nuts to 17 N·m (145 in. lbs.). (11) If necessary, repeat the above steps on the remaining side of the proportioning valve which control the other rear wheel brake. (12) Attach the actuator lever and bracket to the rear axle. (13) Bleed rear brakes. (Refer to 5 - BRAKES STANDARD PROCEDURE) (14) Road test vehicle. CAUTION: Do not attempt to adjust the height sensing proportioning valve. If found to be defective, replace the valve. PROPORTIONING VALVE SPECIFICATIONS WHEEL BASE DRIVE TRAIN SALES CODE BRAKE SYSTEM SPLIT POINT SLOPE INLET PRESSURE PSI OUTLET PRESSURE PSI SWB FWD BRB-BGF 159 DISC/DRUM W/O ANTILOCK VAR. .59 1000 PSI 675-875 PSI REMOVAL - PROPORTIONING VALVE (HEIGHT SENSING) (1) Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve. (2) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the proportioning valve or the brake tubes. (3) Remove the four brake tubes from the inlet and outlet ports of the proportioning valve (Fig. 92). (4) Remove the two bolts attaching the proportioning valve and bracket to the vehicle (Fig. 92). (5) Slide the bracket out from under rear track bar bracket. Lower the valve down enough to pull its actuator rod out of the axle bracket and remove the proportioning valve from the vehicle. Fig. 92 PROPORTIONING VALVE MOUNTING 1 2 3 4 5 - LEFT REAR OUTLET TUBE RIGHT REAR OUTLET TUBE RIGHT REAR INLET TUBE MOUNTING BOLTS LEFT REAR INLET TUBE RS BRAKES - BASE 5 - 59 PROPORTIONING VALVE (Continued) INSTALLATION - PROPORTIONING VALVE (HEIGHT SENSING) (1) Install the end of the actuator rod through the axle bracket grommet and slide the proportioning valve bracket under the rear track bar body bracket (Fig. 92). (2) Install the proportioning valve attaching bolts (Fig. 92). Tighten the attaching bolts to a torque of 54 N·m (40 ft. lbs.). (3) Install the four chassis brake lines into the inlet and outlet ports of the proportioning valve (Fig. 92). Tighten all tube nuts to a torque of 17 N·m (145 in. lbs.). CAUTION: The height sensing proportioning valve is not adjustable. No attempt should be made to adjust it. (4) Bleed the brake system thoroughly to ensure that all air has been expelled from the hydraulic system. (Refer to 5 - BRAKES - BASE - STANDARD PROCEDURE). (5) Lower the vehicle to the ground. (6) Road test the vehicle to verify proper operation of the brake system. 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 at the center of the brake shoe 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. Minimum thickness specifications are cast on the rotor’s unmachined surface (Fig. 93). Limits can also be found in this section’s specification table. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR SPECIFICATIONS) ROTOR DIAGNOSIS AND TESTING - 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 checked and 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. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/ROTORS STANDARD PROCEDURE). 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. Fig. 93 Minimum Brake Rotor Thickness Markings (Typical) 1 - ROTOR MINIMUM THICKNESS MARKING 2 - ROTOR 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 at 12 equal points around the rotor braking surface with a micrometer at a radius approximately 25 mm (1 inch) from edge of rotor (Fig. 94). If thickness measurements vary beyond the specification listed in the specifaction table (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR - SPECIFICATIONS), the rotor should be refaced or replaced. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - STANDARD PROCEDURE). 5 - 60 BRAKES - BASE RS ROTOR (Continued) Fig. 95 Checking Rotor Runout 1 2 3 4 - SPECIAL TOOL SP-1910 10 MILLIMETERS FROM EDGE DISC SURFACE SPECIAL TOOL C-3339 Fig. 94 Checking Rotor For Thickness 1 - CALIPER ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor runouts are separable). To measure rotor runout on the vehicle, first remove the tire and wheel assembly. Reinstall the wheel mounting nuts on the studs, tightening the rotor to the hub. Mount the Dial Indicator, Special Tool C-3339, with Mounting Adaptor, Special Tool SP1910 on steering arm. The dial indicator plunger should contact braking surface of rotor approximately ten millimeters from edge of rotor (Fig. 95). Check lateral runout on both sides of the rotor, marking the low and high spots on both. Runout limits can be found in the specification table in this section. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR - SPECIFICATIONS) If runout is in excess of the specification, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed (Fig. 96). Remove the rotor from the hub. NOTE: Clean the hub face surface before checking runout. This provides a clean surface to get an accurate indicator reading. Fig. 96 Marking Rotor and Wheel Stud 1 - CHALK MARK Mount Dial Indicator, Special Tool C-3339, and Mounting Adaptor, Special Tool SP-1910, to the steering knuckle. Position the indicator stem so it contacts the hub face near the outer diameter. Care must be taken to position stem outside of the stud circle, but inside of the chamfer on the hub rim (Fig. 97). Hub runout should not exceed 0.03 mm (0.0012 inch). If runout exceeds this specification, the hub must be replaced. (Refer to 2 - SUSPENSION/ FRONT/HUB / BEARING - REMOVAL)(Refer to 2 SUSPENSION/REAR/HUB / BEARING - REMOVAL) BRAKES - BASE RS 5 - 61 ROTOR (Continued) Recheck brake rotor runout to see if the runout is now within specifications. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR - SPECIFICATIONS) If runout is not within specifications, reface or replace the brake rotor. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - STANDARD PROCEDURE) STANDARD PROCEDURE - BRAKE ROTOR MACHINING NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Fig. 97 Checking Hub Runout 1 - HUB SURFACE 2 - SPECIAL TOOL C-3339 3 - SPECIAL TOOL SP-1910 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 (Fig. 99), or replaced. If the hub runout does not exceed this specification, install the rotor back on the hub, aligning the chalk marks on the rotor with a wheel mounting stud, two studs apart from the original stud (Fig. 98). Tighten nuts in the proper sequence and torque to specifications. Fig. 99 On-Car Brake Lathe 1 - ON-CAR BRAKE LATHE The use of a hub-mounted on-car brake lathe is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle’s hub and bearing. Fig. 98 Index Rotor And Wheel Stud 1 - CHALK MARK NOTE: All rotors have markings for minimum allowable thickness cast on an un-machined surface of the rotor (Fig. 100) (Fig. 101). Minimum thickness specifications can also be found in the specification table in this section. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR - SPECIFICATIONS) 5 - 62 BRAKES - BASE RS ROTOR (Continued) REMOVAL - FRONT BRAKE ROTOR (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance. (2) Remove the front wheel and tire assembly. (3) Remove the two mounting bolts securing the disc brake caliper adapter with brake caliper to the steering knuckle (Fig. 102). Fig. 100 Front Brake Rotor 1 - ROTOR MINIMUM THICKNESS MARKING 2 - ROTOR Fig. 102 Front Brake Mounting Fig. 101 Rear Brake Rotor Minimum Thickness Markings 1 - ROTOR MINIMUM THICKNESS AND DRUM MAXIMUM DIAMETER SPECIFICATIONS ARE SHOWN ON THIS SURFACE 2 - REAR ROTOR 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. Before 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 section’s specification table. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/ROTOR SPECIFICATIONS) 1 2 3 4 5 6 7 - BRAKE ROTOR - HUB AND BEARING - STEERING KNUCKLE - ADAPTER MOUNTING BOLTS - BRAKE CALIPER - ADAPTER - CLIP (4) Remove the disc brake caliper and adapter as an assembly from the steering knuckle (Fig. 102). 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 retainer clips from the wheel mounting studs. (6) Remove brake rotor from hub by pulling it straight off wheel mounting studs (Fig. 102). INSTALLATION - FRONT BRAKE ROTOR (1) Install the brake rotor back on the hub and bearing (Fig. 102). (2) Install brake caliper and adapter back over brake rotor aligning adapter with mounting holes on steering knuckle (Fig. 102). (3) Install the two adapter mounting bolts securing the adapter to the steering knuckle. Tighten the mounting bolts to 169 N·m (125 ft. lbs.) torque. (4) Install wheel and tire assembly on vehicle. Tighten the wheel mounting lug nuts in proper sequence until all nuts are torqued to half specifica- BRAKES - BASE RS 5 - 63 ROTOR (Continued) tion, then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (5) Lower vehicle to the ground. SPECIFICATIONS BRAKE ROTOR 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. LIMITS/SPECIFICATIONS Braking Rotor Rotor Thickness Minimum Rotor Thickness Rotor Thickness Variation Rotor Runout* Front Rotor Disc/Drum Brakes (TRW) 27.87–28.13 mm 1.097-1.107 in. 25.3 mm 0.996 in. 0.009 mm 0.0004 in. 0.035 mm 0.0014 in. Front Rotor Disc/Disc Brakes (Teves) 27.90–28.10 mm 1.098-1.106 in. 25.3 mm 0.996 in. 0.008 mm 0.0003 in. 0.035 mm 0.0014 in. Rear Rotor 12.4–12.6 mm 0.488 -0.496 in. 11.25 mm 0.443 in. 0.013 mm 0.0005 in. 0.14 mm 0.0055 in. * TIR Total Indicator Reading (Measured On Vehicle) BRAKE ROTOR - EXPORT NOTE: Use the following information on all 4 wheel disc brake vehicles that are equipped with BR3 sales code. 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. LIMITS/SPECIFICATIONS Brake Rotor Rotor Thickness Minimum Rotor Thickness Rotor Thickness Variation Rotor Runout * Front 27.9-28.1 mm 1.098 -1.106 in. 26.5 mm 1.043 in 0.010 mm 0.0004 in. 0.080 mm 0.0031 in. Rear 12.4-12.6 mm 0.488-0.496 in. 11.25 mm 0.443 in. 0.013 mm 0.0005 in. 0.14 mm 0.0055 in. * TIR Total Indicator Reading (Measured On Vehicle) 5 - 64 BRAKES - BASE SUPPORT PLATE - DRUM BRAKE REMOVAL (1) Using a brake pedal depressor, move and secure brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of master cylinder when brake tube is remove from wheel cylinder. (2) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (3) Remove wheel and tire assembly. (4) Disconnect brake tube from rear of wheel cylinder. Cap open ends (5) Remove brake drum. (6) Remove brake shoes from brake support plate. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ BRAKE PADS/SHOES - REMOVAL). (7) Remove the 2 bolts attaching the wheel cylinder to the brake support plate. (8) Remove the wheel cylinder from the brake support plate. (9) Disconnect the park brake cable from the park brake actuation lever. (10) Using a suitable tool such as a 14 mm box wrench (Fig. 103) or an aircraft type hose clamp, compress the flared legs on park brake cable retainer. Then pull the park brake cable out of brake support plate. RS (11) Remove the rear hub and bearing. (Refer to 2 SUSPENSION/REAR/HUB / BEARING REMOVAL) (12) Remove the rear brake support plate from the rear axle. INSTALLATION (1) Install the 4 hub and bearing to axle mounting bolts into the mounting holes in the flange of the rear axle. (2) Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle (Fig. 104). Fig. 104 Brake Support Plate Mounted On Bearing Attaching Bolts 1 - REAR BRAKE SUPPORT PLATE 2 - HUB/BEARING MOUNTING BOLTS Fig. 103 Removing Park Brake Cable From Brake Support Plate 1 2 3 4 - PARK BRAKE CABLE CABLE RETAINER 14 mm BOX WRENCH BRAKE SUPPORT PLATE (3) Install the rear hub and bearing (and connect wheel speed sensor where applicable) stopping short of installing the brake drum. (Refer to 2 - SUSPENSION/REAR/HUB / BEARING - INSTALLATION) (4) Install the rear park brake cable into its mounting hole in the rear brake support plate. (5) Install the park brake cable on the park brake actuation lever. (6) Apply sealant such as Mopar Gasket-In-A-Tube or equivalent around the wheel cylinder opening in the brake support plate. (7) Install wheel cylinder onto brake support. Install and tighten the wheel cylinder to brake support plate attaching bolts to 8 N·m (75 in. lbs.) torque. (8) Install brake tube into wheel cylinder. Tighten tube nut to a torque of 17 N·m (145 in. lbs.) torque. (9) Install the rear brake shoes on the brake support plate. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES INSTALLATION). (10) Install brake drum. BRAKES - BASE RS 5 - 65 SUPPORT PLATE - DRUM BRAKE (Continued) (11) Install wheel and tire. (12) Tighten wheel stud nuts to 135 N·m (100 ft. lbs.). (13) Adjust drum brake shoes. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - ADJUSTMENTS) (14) Remove brake pedal depressor tool. (15) Bleed the brake system as necessary. (Refer to 5 - BRAKES - BASE - STANDARD PROCEDURE). (16) Lower the vehicle. WHEEL CYLINDERS REMOVAL (1) Using a brake pedal depressor, move and secure brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of master cylinder when brake tube is remove from wheel cylinder. (2) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (3) Remove wheel and tire assembly. (4) Disconnect brake tube from rear of wheel cylinder. Cap open ends (5) Remove brake drum. (6) Remove brake shoes from brake support plate (Discard if contaminated).(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES REMOVAL) (7) Remove the 2 bolts attaching the wheel cylinder to the brake support plate. (8) Remove the wheel cylinder from the brake support plate. (3) Install brake tube into wheel cylinder. Tighten tube nut to a torque of 17 N·m (145 in. lbs.) torque. (4) Install the rear brake shoes on the brake support plate. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES INSTALLATION). (5) Install brake drum. (6) Install wheel and tire. Install and tighten wheel lug nuts to 135 N·m (100 ft. lbs.). (7) Adjust drum brake shoes. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - ADJUSTMENTS) (8) Remove brake pedal depressor tool. (9) Bleed the brake system as necessary. (Refer to 5 - BRAKES - BASE - STANDARD PROCEDURE). (10) Lower vehicle. PARKING BRAKE DESCRIPTION DESCRIPTION The parking brake system is operated by a foot operated parking brake lever. The parking brake lever is mounted on the body of the vehicle to the left of the brake pedal (Fig. 105). It is a automatic-adjusting type lever. INSPECTION With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. INSTALLATION (1) Apply sealant such as Mopar Gasket-In-A-Tube or equivalent around the wheel cylinder opening in the brake support plate. (2) Install wheel cylinder onto brake support. Install and tighten the wheel cylinder to brake support plate attaching bolts to 8 N·m (75 in. lbs.) torque. Fig. 105 Parking Brake Lever (Pedal) 1 2 3 4 5 6 - PARK BRAKE PEDAL ASSEMBLY PARK BRAKE PEDAL CARPET FRONT PARK BRAKE CABLE SEAL FLOOR PAN 5 - 66 BRAKES - BASE RS PARKING BRAKE (Continued) The vehicle has four flexible steel parking brake cables. They are: • Front • Intermediate • Left rear • Right rear The front parking brake cable extends from the parking brake lever. A steel equalizer bracket connects the front parking brake cable to the left rear and intermediate cable. The intermediate cable is connected to the right rear cable using a parking brake cable connector. On vehicles equipped with rear drum brakes, the rear service brakes also act as the vehicle’s parking brakes. Vehicles equipped with rear disc brakes use a small duo-servo brake assembly mounted to the each rear disc brake caliper adapter as the parking brake. The inside of the brake rotor (hat section of drum-inhat style brake rotor) is used as the parking brake drum. ing the parking brake lever (pedal) or the parking brake cables. This parking brake lever (pedal) mechanism is designed so that the adjuster mechanism will rotate only half a turn when the tension is released from the parking brake cable. This eliminates the requirement to lock out the automatic adjuster when servicing the parking brake lever (pedal) mechanism and cables. Use the following procedure to release the tension from the parking brake cables and the automatic adjuster in the parking brake lever (pedal) mechanism. (1) Grasp the exposed section of the front parking brake cable and pull rearward on it. While holding the park brake in this position, install a pair of locking pliers on the front parking brake cable just rearward of the second body outrigger bracket (Fig. 106). DESCRIPTION - EXPORT The parking brake system on this vehicle features a hand-operated parking brake lever. The lever is located between the two front seats and requires a special front cable. OPERATION The automatic-adjusting feature in the foot operated parking brake lever continuously applies minimal tension to the parking brake cables when the parking brake lever is in the released position to keep them in adjustment at all times. Due to this feature, the parking brake cables require no periodic adjustment. When the parking brake lever is applied, the cables are pulled, thus applying the brake shoes (rear drum brakes) or parking brake shoes (rear disc brakes) at each rear wheel. The brake shoes are mechanically operated by an internal lever and strut connected to the rear parking brake cables. An equalizer bracket is used at the rear end of the front parking brake cable to distribute tension equally to each parking brake cable. STANDARD PROCEDURE STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION RELEASE The parking brake lever (pedal) mechanism used in this vehicle is designed so that the automatic adjuster is not required to be locked out when servic- Fig. 106 Locking Out Automatic Adjuster 1 - PARK BRAKE CABLE 2 - REAR BODY OUTRIGGER BRACKET 3 - LOCKING PLIERS (2) Remove the left rear and intermediate parking brake cables from the parking brake cable equalizer (Fig. 107). (3) Remove the equalizer from the front parking brake cable. (4) Remove the locking pliers from the front parking brake cable. This will allow the adjuster in the parking brake lever (pedal) mechanism to rotate around to its stop. This will remove the tension from the adjuster and front park brake cable (Refer to 5 BRAKES/PARKING BRAKE - STANDARD PROCEDURE). BRAKES - BASE RS 5 - 67 PARKING BRAKE (Continued) CABLES - PARKING BRAKE REMOVAL REMOVAL - PARKING BRAKE CABLE (FRONT) Fig. 107 Parking Brake Cable Attachment To Equalizer 1 2 3 4 5 - (1) Raise vehicle on jackstands or centered on a hoist. (Refer to LUBRICATION & MAINTENANCE/ HOISTING - STANDARD PROCEDURE). (2) Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. (Refer to 5 - BRAKES - STANDARD PROCEDURE). (3) Remove the intermediate and left rear park brake cable from the park brake cable equalizer (Fig. 108). EQUALIZER LEFT REAR PARKING BRAKE CABLE LOCKING NUT INTERMEDIATE PARKING BRAKE CABLE FRONT PARKING BRAKE CABLE STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET The parking brake lever (pedal) mechanism used in this vehicle is designed so that the automatic adjuster is not required to be locked out when servicing the parking brake lever (pedal) or the parking brake cables. (1) Grasp the exposed section of the front parking brake cable and pull rearward on it. While holding the park brake in this position, install a pair of locking pliers on the front parking brake cable just rearward of the second body outrigger bracket (Fig. 106). (2) Install the equalizer on the front parking brake cable. (3) Install the left rear and intermediate park brake cable in the correct location on the parking brake cable equalizer (Fig. 107). (4) Remove the locking pliers from the front parking brake cable. This will allow the adjuster in the park brake lever (pedal) mechanism to tension the park brake cables. (5) Apply and release the parking brake lever (pedal) one time. This will seat the parking brake cables and allow the auto adjuster in the parking brake lever (pedal) mechanism to correctly tension the parking brake cables. Fig. 108 Park Brake Cable Attachment To Equalizer 1 2 3 4 5 - EQUALIZER LEFT REAR PARKING BRAKE CABLE LOCKING NUT INTERMEDIATE PARKING BRAKE CABLE FRONT PARKING BRAKE CABLE (4) Remove the front park cable housing retainer from body outrigger bracket (Fig. 109). Cable is removable by sliding a 14 mm box wrench over cable retainer and compressing the three retaining fingers. Alternate method is to use an aircraft type hose clamp and screwdriver. (5) Lower vehicle. (6) Remove the left front door sill molding. (7) Remove the left front kick panel for access to the park brake cable and park brake pedal assembly. (8) Lift floor mat for access to park brake cable and floor pan. Pull the seal and the park brake cable (Fig. 110) out of the floor pan of vehicle. (9) Pull parking brake cable strand end forward and disconnect button from clevis. Tap cable housing end fitting out of pedal assembly bracket. 5 - 68 BRAKES - BASE RS CABLES - PARKING BRAKE (Continued) REMOVAL - PARKING BRAKE CABLE (INTERMEDIATE) (1) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (2) Manually lock out the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. (Refer to 5 - BRAKES - STANDARD PROCEDURE). Once the cable is released from the equalizer, do not remove the locking pliers until reinstallation of the cable is complete. (3) Remove the intermediate parking brake cable from the parking brake cable equalizer (Fig. 111). Fig. 109 Front Park Brake Cable Attachment To Body 1 2 3 4 - CABLE HOUSING RETAINER BODY OUTRIGGER BRACKET PUSH WRENCH OVER END OF RETAINER HERE FRONT PARK BRAKE CABLE Fig. 111 Parking Brake Cable Attachment To Equalizer 1 2 3 4 5 Fig. 110 Front Park Brake Cable At Floor Pan 1 2 3 4 5 6 - PARK BRAKE PEDAL ASSEMBLY PARK BRAKE PEDAL CARPET FRONT PARK BRAKE CABLE SEAL FLOOR PAN (10) Remove cable retainer from the parking brake lever (pedal) assembly bracket. (11) Pull front parking brake cable assembly out of vehicle through hole in floor pan. - EQUALIZER LEFT REAR PARKING BRAKE CABLE LOCKING NUT INTERMEDIATE PARKING BRAKE CABLE FRONT PARKING BRAKE CABLE (4) Remove the locking nut securing the intermediate cable housing to the side bracket on the frame rail (Fig. 111). (5) Remove the intermediate parking brake cable from the cable connector attaching it to the right rear parking brake cable (Fig. 112). Remove the locking nut securing the intermediate cable housing to the side bracket on the frame rail (Fig. 112). (6) If the vehicle is a short-wheel-base model, it will be necessary to loosen and lower the fuel tank far enough to remove the intermediate parking brake cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - REMOVAL). (7) Remove the intermediate parking brake cable from the side brackets and vehicle. RS BRAKES - BASE 5 - 69 CABLES - PARKING BRAKE (Continued) Fig. 112 Intermediate Cable Attachment To Right 1 - RIGHT REAR PARKING BRAKE CABLE 2 - LOCKING NUT 3 - INTERMEDIATE PARKING BRAKE CABLE Fig. 113 Locking Out Automatic Adjuster 1 - PARK BRAKE CABLE 2 - REAR BODY OUTRIGGER BRACKET 3 - LOCKING PLIERS REMOVAL - PARKING BRAKE CABLE (RIGHT REAR) (1) Raise vehicle on jackstands or centered on a hoist. (Refer to LUBRICATION & MAINTENANCE/ HOISTING - STANDARD PROCEDURE). (2) Remove rear tire and wheel assembly. (3) Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake cable. (4) Create slack in the rear parking brake cables by locking out the automatic adjuster as described here. Grasp an exposed section of front parking brake cable near the equalizer and pull down on it. At this time install a pair of locking pliers on the cable just rearward of the second body outrigger bracket (Fig. 113). (5) Disconnect the right rear parking brake cable from the connector on the intermediate cable (Fig. 114). (6) To remove the right parking brake cable housing from the body bracket, slide a 14 mm box end wrench over the end of cable retainer to compress the retaining fingers (Fig. 115). The alternate method using an aircraft type hose clamp will not work on the right side of the vehicle. (7) Remove the brake shoes from the brake support plate. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - REMOVAL). Fig. 114 Right Rear Cable Connection To Intermediate Cable 1 - RIGHT REAR PARKING BRAKE CABLE 2 - LOCKING NUT 3 - INTERMEDIATE PARKING BRAKE CABLE (8) Disconnect parking brake cable from parking brake actuator lever. (9) Remove the parking brake cable housing retainer from the brake support plate using a 14mm wrench to compress the retaining fingers (Fig. 116). Remove the cable. 5 - 70 BRAKES - BASE RS CABLES - PARKING BRAKE (Continued) (4) Create slack in rear park brake cables by locking out the automatic adjuster as described here. Grasp an exposed section of front park brake cable near the equalizer and pull down on it. Then install a pair of locking pliers on the cable just rearward of the second body outrigger bracket (Fig. 117). Fig. 115 Right Park Brake Cable Removal From Body Bracket 1 2 3 4 - RIGHT REAR BODY BRACKET PARK BRAKE CABLE 14MM WRENCH LEAF SPRING AND BRACKET Fig. 117 Locked Out Park Brake Automatic Adjuster 1 - PARK BRAKE CABLE 2 - REAR BODY OUTRIGGER BRACKET 3 - LOCKING PLIERS (5) Disconnect the left rear parking brake cable from the parking brake cable equalizer (Fig. 118). Fig. 116 Removing Park Brake Cable From Brake Support Plate 1 2 3 4 - PARK BRAKE CABLE RETAINER PARK BRAKE CABLE 14MM BOX WRENCH BRAKE SUPPORT PLATE REMOVAL - PARKING BRAKE CABLE (LEFT REAR) (1) Raise vehicle on jackstands or centered on a hoist. (Refer to LUBRICATION & MAINTENANCE/ HOISTING - STANDARD PROCEDURE). (2) Remove rear tire and wheel assembly. (3) Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake cable. Fig. 118 Parking Brake Cables At Equalizer 1 2 3 4 5 - EQUALIZER LEFT REAR PARKING BRAKE CABLE LOCKING NUT INTERMEDIATE PARKING BRAKE CABLE FRONT PARKING BRAKE CABLE (6) To remove parking brake cable housing from the body bracket, slide a 14 mm box end wrench over retainer end compressing the three fingers (Fig. 119). Alternate method is to use an aircraft type hose clamp. BRAKES - BASE RS 5 - 71 CABLES - PARKING BRAKE (Continued) INSTALLATION INSTALLATION - PARKING BRAKE CABLE (FRONT) Fig. 119 Parking Brake Cable Removal From Body Bracket 1 2 3 4 5 - LEFT REAR PARK BRAKE CABLE BODY BRACKET LEAF SPRING MOUNTING BRACKET CABLE RETAINER 14MM BOX WRENCH (7) Remove the brake shoes from the brake support plate. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - REMOVAL). (8) Disconnect parking brake cable from parking brake actuator lever. (9) Remove the parking brake cable housing retainer from the brake support plate using a 14mm wrench to compress the retaining fingers (Fig. 120). (1) Pass front parking brake cable assembly through hole in floor pan from the inside of the vehicle. (2) Pass cable strand button through the hole in the lever (pedal) assembly bracket. (3) Install cable retainer onto the park brake cable and then install cable retainer into pedal assembly bracket. (4) Install the end of the park brake cable into the retainer previously installed into the park brake pedal bracket. (5) Install cable strand button into the clevis on the park brake pedal mechanism. (6) Install the front park brake cable floor pan seal into hole in floor pan. Seal is to be installed so the flange on the seal is flush with the floor pan (Fig. 110). Fold carpeting back down on floor. (7) Raise vehicle. (8) Insert brake cable and housing into body outrigger bracket making certain that housing retainer fingers lock the housing firmly into place (Fig. 109). (9) Manually reset the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. (Refer to 5 - BRAKES - STANDARD PROCEDURE). (10) Assemble the park brake cables onto the park brake cable equalizer (Fig. 108). (11) Lower vehicle and apply the park brake pedal 1 time. This will seat the parking brake cables. INSTALLATION - PARKING BRAKE CABLE (INTERMEDIATE) Fig. 120 Removing Parking Brake Cable From Brake Support Plate 1 2 3 4 - PARK BRAKE CABLE RETAINER PARK BRAKE CABLE 14MM BOX WRENCH BRAKE SUPPORT PLATE (1) Install the ends of the park brake cables through the frame rails and into the side brackets. (2) Install the locking nuts at each end of the cable and securely tighten (Fig. 111) (Fig. 112). (3) If the vehicle is a short-wheel-base model, it will be necessary to reinstall the fuel tank to its normal mounting position. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK INSTALLATION). (4) Install the intermediate parking brake cable on the cable connector at the right rear parking brake cable (Fig. 112). (5) Install the intermediate park brake cable on the cable equalizer (Fig. 111). (6) Remove the locking pliers from the front park brake cable. This will activate the automatic adjuster and correctly adjust the parking brake cables. 5 - 72 BRAKES - BASE RS CABLES - PARKING BRAKE (Continued) (7) Install and position the foam collar on the parking brake cable to prevent it from rattling against the vehicle’s floor. (8) Lower the vehicle and apply the park brake pedal 1 time, this will seat the park brake cables. (7) Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. (8) Apply and release park brake pedal 1 time. This will seat the park brake cables. INSTALLATION - PARKING BRAKE CABLE (RIGHT REAR) ADJUSTMENTS (1) Install the rear parking brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. (2) Attach the parking brake cable onto the parking brake actuator lever. (3) Install the brake shoes on the rear brake support plate. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES INSTALLATION). (4) Insert cable housing retainer into body outrigger bracket making certain that cable housing retainer fingers lock the housing firmly into place. (5) Connect the right rear parking brake cable to the connector on the intermediate parking brake cable (Fig. 114). (6) Install the brake drum, then the wheel and tire assembly. (7) Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. (8) Lower the vehicle. (9) Apply and release park brake pedal 1 time. This will seat the park brake cables. INSTALLATION - PARKING BRAKE CABLE (LEFT REAR) (1) Install the rear parking brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. (2) Attach the parking brake cable onto the park brake actuator lever. (3) Install the brake shoes on the rear brake support plate. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES INSTALLATION). (4) Insert cable housing retainer into body outrigger bracket making certain that cable housing retainer fingers lock the housing firmly into place. (5) Connect rear parking brake cable to the equalizer bracket (Fig. 118). (6) Install brake drum, and wheel and tire assembly. ADJUSTMENT - PARKING BRAKE CABLES The park brake cables on this vehicle have an automatic self adjuster built into the park brake pedal mechanism. When the foot operated park brake pedal is in its released (upward most) position, a clock spring automatically adjusts the park brake cables. The park brake cables are adjusted (tensioned) just enough to remove all the slack from the cables. The automatic adjuster system will not over adjust the cables causing rear brake drag. Due to the automatic adjust feature of the park brake pedal, adjustment of the parking brake cables on these vehicles relies on proper drum brake and park brake shoe adjustment. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/DRUM - ADJUSTMENTS) and (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - ADJUSTMENTS). When the park brake pedal is applied the self adjuster is by-passed and the pedal operates normally to engage the park brakes. When a service procedure needs to be performed on the park brake pedal or the park brake cables, the automatic self adjuster can be manually locked out by the service technician. CABLES - PARKING BRAKE (EXPORT) REMOVAL - FRONT CABLE (Refer to 5 - BRAKES - BASE/PARKING BRAKE/ LEVER - REMOVAL) INSTALLATION - FRONT CABLE (Refer to 5 - BRAKES - BASE/PARKING BRAKE/ LEVER - INSTALLATION) LEVER - PARKING BRAKE REMOVAL (1) Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. (Refer to 5 - BRAKES/PARKING BRAKE STANDARD PROCEDURE). (2) Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. BRAKES - BASE RS 5 - 73 LEVER - PARKING BRAKE (Continued) (3) Remove sill scuff plate from left door sill. (4) Remove the left side kick panel. (5) Remove the silencer panel under the instrument panel. (6) Remove the steering column cover from the lower instrument panel. (7) Remove the reinforcement from the lower instrument panel. (8) Remove the front parking brake cable from the parking brake cable equalizer (Fig. 121). Fig. 122 PARKING BRAKE LEVER MOUNTING 1 - WIRE HARNESS CONNECTOR 2 - LEVER MECHANISM 3 - FRONT CABLE (17) Remove front park brake cable button from park brake pedal mechanism. Tap end housing for front park brake cable out of park brake pedal mechanism. Fig. 121 Parking Brake Cable Equalizer 1 2 3 4 5 - EQUALIZER LEFT REAR PARKING BRAKE CABLE LOCKING NUT INTERMEDIATE PARKING BRAKE CABLE FRONT PARKING BRAKE CABLE (9) Remove tension from front park brake cable. Tension is removed by releasing the locking pliers from the front park brake cable. (10) Remove the 3 bolts mounting the wiring junction block to the instrument panel. NOTE: When removing the lower mounting bolt, push the park brake pedal down 5 clicks to access the lower mounting bolt. (11) Remove the lower bolt mounting the park brake pedal to the body (Fig. 122). (12) Remove the forward nut mounting the park brake pedal to the body (Fig. 122). (13) Remove the upper bolt mounting the park brake pedal to the body (Fig. 122). (14) Pull downward on front park brake cable while rotating park brake pedal mechanism out from behind junction block. (15) Remove park brake pedal release link from park brake mechanism. (16) Remove the warning lamp ground switch connector from the park brake pedal mechanism (Fig. 122). INSTALLATION (1) Install park brake cable end housing into park brake pedal mechanism. (2) Install cable retainer onto the park brake cable strand and then install retainer into pedal bracket. (3) Install cable strand button into the clevis on the park brake pedal mechanism. (4) Install wiring harness connector on warning indicator lamp ground switch. (5) Install the park brake release rod on the release mechanism of the park brake pedal. (6) Position the park brake pedal mechanism into its installed position on the body of the vehicle. (7) Loosely install the top bolt mounting the park brake pedal mechanism to the body (Fig. 122). (8) Loosely install the forward nut mounting the park brake pedal mechanism to the body (Fig. 122). (9) Loosely install the lower bolt mounting the park brake pedal mechanism to the body (Fig. 122). (10) Tighten pedal mechanism attaching bolts and nut to 28 N·m (250 in. lbs.). (11) Verify that the park brake pedal is in the fully released (full up) position. (12) Raise vehicle. (13) Install the front park brake cable on the park brake cable equalizer (Fig. 121). 5 - 74 BRAKES - BASE RS LEVER - PARKING BRAKE (Continued) NOTE: If the original lever assembly is being used, the lever mechanism auto adjuster spring tension will need to be reset. (Refer to 5 - BRAKES/PARKING BRAKE - STANDARD PROCEDURE) (14) Lower vehicle. (15) Remove the lock-out pin (if a new lever has been installed) from the automatic cable adjuster on the park brake pedal mechanism. (16) Install the electrical junction block on the instrument panel. (17) Install the reinforcement on the lower instrument panel. (18) Install the steering column lower cover on the lower instrument panel. (19) Install the silencer panel under the instrument panel. (20) Install the left side kick panel. (21) Install the sill scuff plate on the lower sill of the left door. (22) Install the negative (ground) cable on the battery. (23) Cycle the park brake pedal one time. This will seat the park brake cables and will allow the automatic self adjuster to properly tension the park brake cables. Fig. 123 Locking Out Automatic Adjuster 1 - PARK BRAKE CABLE 2 - REAR BODY OUTRIGGER BRACKET 3 - LOCKING PLIERS LEVER - PARKING BRAKE (EXPORT) REMOVAL - PARKING BRAKE LEVER AND FRONT CABLE (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Grasp the exposed section of the front parking brake cable and pull rearward on it. While holding the park brake in this position, install a pair of locking pliers on the front parking brake cable just rearward of the second body outrigger bracket (Fig. 123). (3) Remove the left rear and intermediate parking brake cables from the parking brake cable equalizer (Fig. 124). (4) Remove the equalizer from the front parking brake cable. (5) Remove the locking pliers from the front parking brake cable. This will allow the adjuster in the parking brake lever mechanism to rotate around to its stop and remove the tension from the adjuster and front park brake cable. (6) Remove the front parking brake cable housing from body outrigger bracket. Cable is removable by sliding a 14 mm box wrench over the cable retainer and compressing the three retaining fingers. Alternate method: Use an aircraft type hose clamp and screwdriver. Fig. 124 Parking Brake Cable Equalizer 1 2 3 4 5 - EQUALIZER LEFT REAR PARKING BRAKE CABLE LOCKING NUT INTERMEDIATE PARKING BRAKE CABLE FRONT PARKING BRAKE CABLE (7) Remove the four mounting nuts from the bottom of the parking brake lever bracket. (8) Lower vehicle. (9) Remove the floor console. (Refer to 23 - BODY/ INTERIOR/FLOOR CONSOLE - REMOVAL) (10) If equipped with a manual transaxle, remove the gearshift mechanism. (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL/SHIFT MECHANISM - REMOVAL) (11) Unhook the end of the parking brake cable from the lever mechanism. BRAKES - BASE RS 5 - 75 LEVER - PARKING BRAKE (EXPORT) (Continued) (12) Compress the parking brake cable retainer by sliding a 14 mm wrench over the cable retainer and compress the three (3) retaining fingers. (13) Remove the three screws from the parking brake grommet on the floor pan of the passenger compartment. (14) Lift the parking brake lever and slide the parking brake cable out. (15) Pull the cable through the floor pan from inside the vehicle. (12) Remove the locking pliers from the front parking brake cable. This will allow the adjuster in the park brake lever mechanism to tension the parking brake cables. (13) Lower the vehicle. (14) Apply and release the parking brake lever one time. This will seat the parking brake cables and allow the auto adjuster in the parking brake lever mechanism to correctly tension the parking brake cables. INSTALLATION - PARKING BRAKE LEVER AND FRONT CABLE SHOES - PARKING BRAKE (1) Pass the parking brake cable down through the hole in the floor pan from inside of vehicle. (2) Pass cable end button through the hole in the lever bracket and press the cable housing into the hole until all three retaining fingers lock the cable to the lever bracket. (3) Hook the end of the parking brake cable on the parking brake lever mechanism. (4) Press the cable grommet into the hole in the floor pan and install the three screws securing it to the floor pan. (5) If equipped with a manual transaxle, install the gearshift mechanism. (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL/SHIFT MECHANISM - INSTALLATION) (6) Install the floor console. (Refer to 23 - BODY/ INTERIOR/FLOOR CONSOLE - INSTALLATION) (7) Raise the vehicle. (8) Install the four mounting nuts securing the parking brake lever bracket in place. (9) Install the front park cable housing retainer to the body outrigger bracket. Press the cable housing into the outrigger hole until all three retaining fingers lock the cable in place. (10) Grasp the exposed section of the front parking brake cable and pull rearward on it. While holding the park brake in this position, install a pair of locking pliers on the front parking brake cable just rearward of the second body outrigger bracket. (11) Install the equalizer on the front parking brake cable and install the left rear and intermediate park brake cable in the correct location on the parking brake cable equalizer (Fig. 124). REMOVAL (1) AWD only - Set the parking brake. The parking brake is set to keep the hub/bearing and axle shaft from rotating when loosening the hub nut. (2) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (3) Remove the wheel and tire assembly. (4) AWD only - Remove the cotter pin and nut retainer (Fig. 125) from the stub shaft of the outer C/V joint. Fig. 125 Cotter Pin And Nut Retainer 1 2 3 4 5 - CALIPER COTTER PIN ROTOR NUT RETAINER OUTER C/V JOINT 5 - 76 BRAKES - BASE RS SHOES - PARKING BRAKE (Continued) (5) AWD only - Remove the spring washer (Fig. 126) from the stub shaft of the outer C/V joint. ing pliers on the front park brake cable just rearward of the second body outrigger bracket (Fig. 128). Fig. 126 Spring Washer 1 2 3 4 - HUB NUT STUB SHAFT ROTOR SPRING WASHER (6) AWD only - Remove the hub nut and washer (Fig. 127) from the stub shaft of the outer C/V joint. Fig. 128 Locking Out Automatic Adjuster 1 - PARK BRAKE CABLE 2 - REAR BODY OUTRIGGER BRACKET 3 - LOCKING PLIERS (9) Remove the disc brake caliper to adapter guide pin bolts (Fig. 129). Fig. 129 Removing Caliper Guide Pin Bolts Fig. 127 Hub Nut And Washer 1 2 3 4 5 - CALIPER - HUB NUT - WASHER - ROTOR - ADAPTER (7) Release the parking brake. (8) Create slack in the rear park brake cables by locking the out the automatic adjuster as described. Grasp the exposed section of front park brake cable and pull downward on it. Then install a pair of lock- 1 2 3 4 5 - DISC BRAKE CALIPER - ADAPTER - AXLE - GUIDE PIN BOLTS - DRIVESHAFT (AWD MODELS ONLY) (10) Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter (Fig. 130). BRAKES - BASE RS 5 - 77 SHOES - PARKING BRAKE (Continued) Fig. 130 Removing/Installing Caliper 1 2 3 4 5 6 7 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST - DISC BRAKE CALIPER - ADAPTER ABUTMENT - OUTBOARD BRAKE SHOE HOLD DOWN CLIP - OUTBOARD BRAKE SHOE - ROTOR - ADAPTER (11) Support caliper to prevent the weight of the caliper from damaging the flexible brake hose (Fig. 131). Fig. 132 Park Brake Cable Attachment To Actuator 1 2 3 4 5 6 7 - ADAPTER - PARK BRAKE CABLE - ACTUATOR - AXLE - DRIVESHAFT - PARK BRAKE CABLE RETAINER - HORSESHOE CLIP (15) Remove the end of the park brake cable from the adapter. Park brake cable is removed from adapter using a 1/2 wrench slipped over the park brake cable retainer as show in (Fig. 133) to compress the locking tabs on the park brake cable retainer. Fig. 131 Correctly Supported Caliper 1 2 3 4 5 - WIRE - CALIPER - ADAPTER - ROTOR - INNER FENDER (12) Remove the rotor from the hub/bearing. (13) Remove the park brake cable mounting bolt to adapter. (14) Remove the end of the park brake cable from the actuator lever on the adapter (Fig. 132). Fig. 133 Park Brake Cable Removal From Adapter 1 2 3 4 5 - DRIVESHAFT - 1/2” WRENCH - PARK BRAKE CABLE - PARK BRAKE CABLE RETAINER - ADAPTER 5 - 78 BRAKES - BASE RS SHOES - PARKING BRAKE (Continued) (16) AWD only - Remove ABS wheel speed sensor head from hub/bearing (Fig. 134). Fig. 135 Sensor Connection At Hub And Bearing Fig. 134 Speed Sensor Attaching Bolt (AWD) 1 2 3 4 5 6 - ADAPTER - TONE WHEEL - WHEEL SPEED SENSOR - AXLE - BOLT - DRIVESHAFT (17) FWD only - Remove the ABS wheel speed sensor from the hub/bearing in the following fashion: (a) Remove secondary (yellow) retaining clip at rear of wheel speed sensor head (Fig. 135). (b) Push up on metal retaining clip (Fig. 135) until it bottoms. This will release wheel speed sensor head from hub and bearing. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. (c) Remove wheel speed sensor from hub/bearing. (18) Remove the hub/bearing-to-axle mounting bolts (Fig. 136). (19) Remove the hub/bearing (Fig. 137). 1 - SECONDARY SENSOR RETAINING CLIP 2 - METAL SENSOR RETAINING CLIP 3 - HUB AND BEARING Fig. 136 Hub/Bearing Mounting Bolts (AWD Shown) 1 2 3 4 5 - DRIVESHAFT - MOUNTING BOLTS - AXLE - MOUNTING BOLTS - ADAPTER BRAKES - BASE RS 5 - 79 SHOES - PARKING BRAKE (Continued) Fig. 137 Hub/Bearing Removal/Installation (AWD Shown) 1 2 3 4 5 - PARK BRAKE BRAKE SHOE OUTER C/V JOINT HUB/BEARING PARK BRAKE BRAKE SHOE STUB SHAFT CAUTION: Corrosion may occur between the hub/ bearing and the axle flange. If this occurs, the hub/ bearing will be difficult to remove from the axle and disc brake caliper adapter. If the hub/bearing will not come out by pulling on it by hand, don’t not pound on it with a hammer. Pounding on the hub/ bearing will damage it. To remove a hub/bearing that is corroded in place, lightly tap the disc brake caliper adapter using a soft-face hammer. This will remove both the caliper adapter and hub/bearing together from the axle. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1, on the cast housing of hub/ bearing (Fig. 138). Do not position the special tool on the inner race of hub/bearing. Lightly strike the Remover with a hammer to remove the hub/bearing from the caliper adapter. (20) Remove the adapter from the rear axle. (21) Mount the adapter in a vise using the anchor boss for the park brake cable (Fig. 139). Fig. 138 Hub/Bearing Removal From Caliper Adapter 1 2 3 4 - SPECIAL TOOL 8214-1 PARK BRAKE CABLE DISC BRAKE CALIPER ADAPTER HUB/BEARING Fig. 139 Adapter Mounted In Vise 1 2 3 4 - ADAPTER - PARK BRAKE CABLE BOSS - VISE - PARK BRAKE BRAKE SHOES 5 - 80 BRAKES - BASE RS SHOES - PARKING BRAKE (Continued) (22) Remove the lower return spring (Fig. 140) from the leading and trailing park brake shoes. (24) Remove the adjuster (Fig. 142) from the leading and trailing park brake shoe. Fig. 140 Lower Return Spring Fig. 142 Brake Shoe Adjuster 1 2 3 4 - ADAPTER - LEADING PARK BRAKE SHOE - RETURN SPRING - TRAILING PARK BRAKE SHOE (23) Remove the hold down spring and pin (Fig. 141) from the leading park brake shoe. 1 - LEADING PARK BRAKE SHOE 2 - ADJUSTER 3 - TRAILING PARK BRAKE SHOE (25) Remove the leading park brake shoe (Fig. 143) from the adapter. Leading brake shoe is removed by rotating the bottom of the brake shoe inward (Fig. 143) until the top of the brake shoe can be removed from the brake shoe anchor. Then remove the upper return springs (Fig. 143) from the leading brake shoe. Fig. 141 Leading Brake Shoe Hold Down Pin And Spring 1 2 3 4 - ADAPTER - LEADING PARK BRAKE SHOE - ALLEN WRENCH - HOLD DOWN SPRING/PIN Fig. 143 Primary Brake Shoe Remove/Install 1 2 3 4 5 - PARK BRAKE ACTUATOR - ANCHOR - LEADING PARK BRAKE SHOE - UPPER RETURN SPRINGS - TRAILING PARK BRAKE SHOE BRAKES - BASE RS 5 - 81 SHOES - PARKING BRAKE (Continued) (26) Remove the upper return springs (Fig. 144) from the trailing park brake shoe. (28) Remove the trailing park brake shoe from the adapter. (29) Remove the park brake shoe actuator from the adapter and inspect for signs of abnormal wear and binding at the pivot point. INSTALLATION (1) Install park brake shoe actuator into adapter. (2) Install the trailing brake shoe on the adapter. NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter. Fig. 144 Upper Return Springs 1 2 3 4 - TRAILING PARK BRAKE SHOE - ADAPTER - PARK BRAKE ACTUATOR - UPPER RETURN SPRINGS (27) Remove the hold down spring and pin (Fig. 145) from the trailing park brake shoe. (3) Install the hold down spring and pin (Fig. 145) on the trailing park brake shoe. (4) Install the upper return springs (Fig. 144) on the trailing park brake shoe. (5) Install the upper return springs on the leading park brake shoe (Fig. 143). Then position the top of the leading park brake shoe at the upper anchor and rotate the bottom of the shoe outward until correctly installed on the adapter. (6) Install the adjuster (Fig. 142) between the leading and trailing park brake shoe. NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter. (7) Install the hold down spring and pin (Fig. 141) on the leading park brake shoe. (8) Install the lower return spring (Fig. 140) on the leading and trailing park brake shoes.When installing the return spring, it is to be installed behind the park brake shoes (Fig. 140). (9) Install the 4 mounting bolts for the adapter and hub/bearing into the bolt holes in the axle. (10) Position the adapter on the 4 mounting bolts installed in the rear axle (Fig. 146). Fig. 145 Trailing Brake Shoe Hold Down Pin And Spring 1 2 3 4 5 - HOLD DOWN SPRING PIN - ADAPTER - PARK BRAKE ACTUATOR - TRAILING PARK BRAKE SHOE - ALLEN WRENCH 5 - 82 BRAKES - BASE RS SHOES - PARKING BRAKE (Continued) Fig. 146 Adapter Installed On Mounting Bolts (AWD Shown) 1 2 3 4 5 - DRIVESHAFT OUTER C/V JOINT - MOUNTING BOLTS - ADAPTER - PARK BRAKE SHOES - MOUNTING BOLTS (11) Install the hub/bearing on the stub shaft of outer C/V joint (AWD only) and into the end of the axle. (Fig. 137). (12) In a progressive crisscross pattern, tighten the 4 hub/bearing mounting bolts until the hub/bearing is squarely seated against the axle. Then tighten the hub/bearing mounting bolts to a torque of 129 N·m (95 ft. lbs.). (13) AWD only - Install the wheel speed sensor on the hub/bearing and adapter. Install the wheel speed sensor attaching bolt (Fig. 134). Tighten the wheel speed sensor attaching bolt to a torque of 12 N·m (105 in. lbs). (14) FWD only - Install the wheel speed sensor in the following fashion: (a) If metal wheel speed sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. (b) Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. (c) Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. (15) Install the park brake cable into its mounting hole in the adapter. Be sure all the locking tabs on the park brake cable retainer are expanded out to ensure the cable will not pull out of the adapter. (16) Install the end of the park brake cable on the park brake actuator lever (Fig. 132). (17) Attach park brake cable to adapter using mounting bolt. (18) Remove the locking pliers (Fig. 128) from the front park brake cable. (19) Adjust the park brake drum-in-hat brake shoes. (Refer to 5 - BRAKES/PARKING BRAKE/ SHOES - ADJUSTMENTS). (20) Install the rotor on the hub/bearing. (21) Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal (Fig. 130). CAUTION: When installing guide pin bolts extreme caution should be taken not to crossthread the caliper guide pin bolts. (22) Install the caliper guide pin bolts (Fig. 129). Tighten the guide pin bolts to a torque of 35 N·m (26 ft. lbs.). (23) AWD only - Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut (Fig. 127) on the stub shaft of the outer C/V joint. (24) AWD only - Set the parking brake. (25) AWD only - Tighten the hub nut to a torque of 244 N·m (180 ft. lbs.). (26) AWD only - Install the spring washer (Fig. 126) on the stub shaft of the outer C/V joint. (27) AWD only - Install the nut retainer and cotter pin (Fig. 125) on the stub shaft of the outer C/V joint. (28) Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (29) Lower vehicle. (30) Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. (31) Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. BRAKES - BASE RS 5 - 83 SHOES - PARKING BRAKE (Continued) ADJUSTMENTS ADJUSTMENT - PARKING BRAKE SHOES (5) Using Brake Shoe Gauge, Special Tool C-3919, or equivalent, accurately measure the inside diameter of the park brake drum portion of the rotor (Fig. 148). CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. (1) Raise vehicle. (2) Remove tire and wheel. (3) Remove disc brake caliper from caliper adapter (Fig. 147). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL). Fig. 148 Measuring Park Brake Drum Diameter (6) Using a ruler that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool (Fig. 149). Fig. 147 Disc Brake Caliper 1 2 3 4 5 - DISC BRAKE CALIPER - ADAPTER - AXLE - GUIDE PIN BOLTS - DRIVESHAFT (AWD MODELS ONLY) (4) Remove rotor from hub/bearing. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. Fig. 149 Reading Park Brake Drum Diameter 1 - SPECIAL TOOL C-3919 2 - RULER 5 - 84 BRAKES - BASE RS SHOES - PARKING BRAKE (Continued) (7) Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 or the equivalent used, so that the outside measurement jaws are set to the reduced measurement (Fig. 150). Fig. 150 Setting Gauge To Park Brake Shoe Measurement 1 - RULER 2 - SPECIAL TOOL C-3919 (8) Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes. (9) Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. (10) Repeat step 8 above and measure shoes in both directions. (11) Install brake rotor on hub and bearing. (12) Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. (13) Install disc brake caliper on caliper adapter (Fig. 147). (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION). (14) Install wheel and tire. (15) Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 N·m (95 ft. lbs.). (16) Lower vehicle. (17) Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. (18) Road test the vehicle to ensure proper function of the vehicle’s brake system. BRAKES - ABS RS 5 - 85 BRAKES - ABS TABLE OF CONTENTS page BRAKES - ABS DESCRIPTION DESCRIPTION - ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - ANTILOCK BRAKE SYSTEM (EXPORT) . . . . . . . . . . . . . . . . . . . DESCRIPTION - ELECTRONIC VARIABLE BRAKE PROPORTIONING . . . . . . . . . . . . . . DESCRIPTION - TRACTION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION OPERATION - ANTILOCK BRAKE SYSTEM . OPERATION - ELECTRONIC VARIABLE BRAKE PROPORTIONING . . . . . . . . . . . . . . OPERATION - TRACTION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . CAUTION CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . SPECIFICATIONS ABS FASTENER TORQUE . . . . . . . . . . . . . . TONE WHEEL RUNOUT . . . . . . . . . . . . . . . WHEEL SPEED SENSOR AIR GAP . . . . . . . FRONT WHEEL SPEED SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL SPEED SENSOR - AWD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 . 85 . 86 . 86 . 86 . 87 . 87 . 88 . 88 . 89 . 89 . 89 . 89 . 89 page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 90 REAR WHEEL SPEED SENSOR - FWD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91 TONE WHEEL INSPECTION - TONE WHEEL . . . . . . . . . . . . . . 92 TRACTION CONTROL SWITCH DIAGNOSIS AND TESTING - TRACTION CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . 92 HYDRAULIC/MECHANICAL OPERATION - HYDRAULIC CIRCUITS AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 99 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 ICU (INTEGRATED CONTROL UNIT) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 100 REMOVAL REMOVAL - LHD . . . . . . . . . . . . . . . . . . . . . 100 REMOVAL - RHD . . . . . . . . . . . . . . . . . . . . . 101 DISASSEMBLY - ICU . . . . . . . . . . . . . . . . . . . 103 ASSEMBLY - ICU . . . . . . . . . . . . . . . . . . . . . . 103 INSTALLATION INSTALLATION - LHD . . . . . . . . . . . . . . . . . 104 INSTALLATION - RHD . . . . . . . . . . . . . . . . . 105 . 90 BRAKES - ABS DESCRIPTION DESCRIPTION - ANTILOCK BRAKE SYSTEM This section covers the physical and operational descriptions and the on-car service procedures for the Mark 20e Antilock Brake System and the Mark 20e Antilock Brake System with traction control. The purpose of the antilock brake system (ABS) is to prevent wheel lockup under braking conditions on virtually any type of road surface. Antilock braking is desirable because a vehicle that is stopped without locking the wheels retains directional stability and some steering capability. This allows the driver to retain greater control of the vehicle during braking. DESCRIPTION - ANTILOCK BRAKE SYSTEM (EXPORT) Four-wheel disc antilock brakes are standard on all models. The Mark 20e antilock brake system is used on all models. Depending on whether the vehicle is a left-hand drive (LHD) or right-hand drive (RHD) model, the integrated control unit (ICU) is located in one of two locations. On LHD models, the ICU is mounted above the front suspension cradle/crossmember below the master cylinder. On RHD models, the ICU is located behind the front suspension cradle/crossmember on the left side of the vehicle. 5 - 86 BRAKES - ABS RS BRAKES - ABS (Continued) DESCRIPTION - ELECTRONIC VARIABLE BRAKE PROPORTIONING Vehicles equipped with ABS use electronic variable brake proportioning (EVBP) to balance front-to-rear braking. The EVBP is used in place of a rear proportioning valve. The EVBP system uses the ABS system to control the slip of the rear wheels in partial braking range. The braking force of the rear wheels is controlled electronically by using the inlet and outlet valves located in the integrated control unit (ICU). DESCRIPTION - TRACTION CONTROL SYSTEM Traction control reduces wheel slip and maintains traction at the driving wheels at speeds below 56 km/h (35 mph) when road surfaces are slippery. The traction control system reduces wheel slip by braking the wheel that is losing traction. HYDRAULIC SHUTTLE VALVES Two pressure relief hydraulic shuttle valves are included on vehicles with traction control. These valves are located inside the HCU and cannot be serviced separately from the HCU. TRACTION CONTROL LAMP The traction control function lamp is located in the transmission range indicator display of the instrument cluster, displaying TRAC, TRAC OFF or neither depending on system mode. The TRAC OFF lamp is controlled by a Traction Control Off switch that is a momentary contact type switch. The Traction Control Off switch is located on the steering column upper shroud. OPERATION OPERATION - ANTILOCK BRAKE SYSTEM There are a few performance characteristics of the Mark 20e Antilock Brake System that may at first seem abnormal, but in fact are normal. These characteristics are described below. NORMAL BRAKING Under normal braking conditions, the ABS functions the same as a standard base brake system with a diagonally split master cylinder and conventional vacuum assist. ABS BRAKING ABS operation is available at all vehicle speeds above 3–5 mph. If a wheel locking tendency is detected during a brake application, the brake system enters the ABS mode. During ABS braking, hydraulic pressure in the four wheel circuits is mod- ulated to prevent any wheel from locking. Each wheel circuit is designed with a set of electric solenoids to allow modulation, although for vehicle stability, both rear wheel solenoids receive the same electrical signal. Wheel lockup may be perceived at the very end of an ABS stop and is considered normal. During an ABS stop, the brakes hydraulic system is still diagonally split. However, the brake system pressure is further split into three control channels. During antilock operation of the vehicle’s brake system, the front wheels are controlled independently and are on two separate control channels, and the rear wheels of the vehicle are controlled together. The system can build and release pressure at each wheel, depending on signals generated by the wheel speed sensors (WSS) at each wheel and received at the controller antilock brake (CAB). NOISE AND BRAKE PEDAL FEEL During ABS braking, some brake pedal movement may be felt. In addition, ABS braking will create ticking, popping, or groaning noises heard by the driver. This is normal and is due to pressurized fluid being transferred between the master cylinder and the brakes. If ABS operation occurs during hard braking, some pulsation may be felt in the vehicle body due to fore and aft movement of the suspension as brake pressures are modulated. At the end of an ABS stop, ABS is turned off when the vehicle is slowed to a speed of 3–4 mph. There may be a slight brake pedal drop anytime that the ABS is deactivated, such as at the end of the stop when the vehicle speed is less than 3 mph or during an ABS stop where ABS is no longer required. These conditions exist when a vehicle is being stopped on a road surface with patches of ice, loose gravel, or sand on it. Also, stopping a vehicle on a bumpy road surface activates ABS because of the wheel hop caused by the bumps. TIRE NOISE AND MARKS Although the ABS system prevents complete wheel lockup, some wheel slip is desired in order to achieve optimum braking performance. Wheel slip is defined as follows: 0 percent slip means the wheel is rolling freely and 100 percent slip means the wheel is fully locked. During brake pressure modulation, wheel slip is allowed to reach up to 25–30 percent. This means that the wheel rolling velocity is 25–30 percent less than that of a free rolling wheel at a given vehicle speed. This slip may result in some tire chirping, depending on the road surface. This sound should not be interpreted as total wheel lockup. Complete wheel lockup normally leaves black tire marks on dry pavement. The ABS will not leave dark RS BRAKES - ABS 5 - 87 BRAKES - ABS (Continued) black tire marks since the wheel never reaches a fully locked condition. However, tire marks may be noticeable as light patched marks. START-UP CYCLE When the ignition is turned on, a popping sound and a slight brake pedal movement may be noticed. The ABS warning lamp will also be on for up to 5 seconds after the ignition is turned on. When the vehicle is first driven off, a humming may be heard or felt by the driver at approximately 20–40 kph (12–25 mph). All of these conditions are a normal function of ABS as the system is performing a diagnosis check. PREMATURE ABS CYCLING Symptoms of premature ABS cycling include: clicking sounds from the solenoid valves; pump/motor running; and pulsations in the brake pedal. Premature ABS cycling can occur at any braking rate of the vehicle and on any type of road surface. Neither the red BRAKE warning lamp, nor the amber ABS warning lamp, illuminate and no fault codes are stored in the CAB. Premature ABS cycling is a condition that needs to be correctly assessed when diagnosing problems with the antilock brake system. It may be necessary to use a DRB scan tool to detect and verify premature ABS cycling. Check the following common causes when diagnosing premature ABS cycling: damaged tone wheels; incorrect tone wheels; damaged steering knuckle wheel speed sensor mounting bosses; loose wheel speed sensor mounting bolts; excessive tone wheel runout; or an excessively large tone wheel-to-wheel speed sensor air gap. Give special attention to these components when diagnosing a vehicle exhibiting premature ABS cycling. After diagnosing the defective component, repair or replace it as required. When the component repair or replacement is completed, test drive the vehicle to verify that premature ABS cycling has been corrected. OPERATION - ELECTRONIC VARIABLE BRAKE PROPORTIONING Upon entry into EVBP the inlet valve for the rear brake circuit is switched on so that the fluid supply from the master cylinder is shut off. In order to decrease the rear brake pressure, the outlet valve for the rear brake circuit is pulsed. This allows fluid to enter the low pressure accumulator (LPA) in the hydraulic control unit (HCU) resulting in a drop in fluid pressure to the rear brakes. In order to increase the rear brake pressure, the outlet valve is switched off and the inlet valve is pulsed. This increases the pressure to the rear brakes. This back-and-forth process will continue until the required slip difference is obtained. At the end of EVBP braking (brakes released) the fluid in the LPA drains back to the master cylinder by switching on the outlet valve and draining through the inlet valve check valve. At the same time the inlet valve is switched on in case of another brake application. The EVBP will remain functional during many ABS fault modes. If both the red BRAKE and amber ABS warning indicators are illuminated, the EVBP may not be functioning. OPERATION - TRACTION CONTROL SYSTEM The traction control module monitors wheel speed. During acceleration, if the module detects front (drive) wheel slip and the brakes are not applied, the module enters traction control mode. Traction control operation proceeds in the following order: (1) Close the normally open isolation valves. (2) Start the pump/motor and supply volume and pressure to the front (drive) hydraulic circuit. (The pump/motor runs continuously during traction control operation.) (3) Open and close the build and decay valves to maintain minimum wheel slip and maximum traction. The cycling of the build and decay valves during traction control is similar to that during antilock braking, except the valves work to control wheel spin by applying the brakes, whereas the ABS function is to control wheel skid by releasing the brakes. If the brakes are applied at anytime during a traction control cycle, the brake lamp switch triggers the controller to switch off traction control. HYDRAULIC SHUTTLE VALVES Two pressure relief hydraulic shuttle valves allow pressure and volume to return to the master cylinder reservoir when not consumed by the build and decay valves. These valves are necessary because the pump/motor supplies more volume than the system requires. TRACTION CONTROL LAMP The traction control system is enabled at each ignition cycle. It may be turned off by depressing the Traction Control Off switch button when the ignition is in the ON position. The traction control function lamp (TRAC OFF) illuminates immediately upon depressing the button. The traction control function lamp illuminates during a traction control cycle, displaying TRAC. If the CAB calculates that the brake temperatures are high, the traction control system becomes inoperative until a time-out period has elapsed. During this 5 - 88 BRAKES - ABS RS BRAKES - ABS (Continued) “thermo-protection mode,” the traction control function lamp illuminates TRAC OFF; note that no trouble code is registered. CAUTION CAUTIONS The ABS uses an electronic control module, the CAB. This module is designed to withstand normal current draws associated with vehicle operation. Care must be taken to avoid overloading the CAB circuits. CAUTION: In testing for open or short circuits, do not ground or apply voltage to any of the circuits unless instructed to do so for a diagnostic procedure. CAUTION: An attempt to remove or disconnect certain system components may result in improper system operation. Only those components with approved removal and installation procedures in this manual should be serviced. CAUTION: If welding work is to be performed on the vehicle, using an electric arc welder, the CAB connector should be disconnected during the welding operation. CAUTION: Many components of the ABS System are not serviceable and must be replaced as an assembly. Do not disassemble any component which is not designed to be serviced. CAUTION: These circuits should only be tested using a high impedance multi-meter or the DRBIIIT scan tool as described in this section. Power should never be removed or applied to any control module with the ignition in the ON position. Before removing or connecting battery cables, fuses, or connectors, always turn the ignition to the OFF position. CAUTION: Only the recommended jacking or hoisting positions for this vehicle are to be used whenever it is necessary to lift a vehicle. Failure to raise a vehicle from the recommended locations could result in lifting a vehicle by the hydraulic control unit mounting bracket. Lifting a vehicle by the hydraulic control unit mounting bracket will result in damage to the mounting bracket and the hydraulic control unit. CAUTION: The CAB 24-way connector should never be connected or disconnected with the ignition switch in the ON position. CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surface, wash off with water immediately. CAUTION: This vehicle utilizes active wheel speed sensors. Do not apply voltage to wheel speed sensors at any time. STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING CAUTION: Use only factory wiring harnesses. Do not cut or splice wiring to the brake circuits. The addition of aftermarket electrical equipment (car phone, radar detector, citizen band radio, trailer lighting, trailer brakes, etc.) on a vehicle equipped with antilock brakes may affect the function of the antilock brake system. CAUTION: When performing any service procedure on a vehicle equipped with ABS, do not apply a 12-volt power source to the ground circuit of the pump motor in the HCU. Doing this will damage the pump motor and will require replacement of the entire HCU. The base brake’s hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. 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 DOT 3 brake fluid as required. The 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. BRAKES - ABS RS 5 - 89 BRAKES - ABS (Continued) 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. 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 DRBIIIt 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 DRB, check to make sure the CAB does not have any fault codes stored. If it does, clear them using the DRB. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. 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. (4) Bleed the base brake system using the standard pressure or manual bleeding procedure. (Refer to 5 - BRAKES - BASE - STANDARD PROCEDURE) (5) Using the DRB, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, 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 reservoir 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. SPECIFICATIONS ABS FASTENER TORQUE (Refer to 5 - BRAKES - BASE - SPECIFICATIONS) TONE WHEEL RUNOUT DESCRIPTION SPECIFICATION Front Tone Wheel Maximum Runout 0.15 mm (0.006 in.) Rear Tone Wheel Maximum Runout 0.15 mm (0.006 in.) WHEEL SPEED SENSOR AIR GAP DESCRIPTION SPECIFICATION Front Sensor 0.35 – 1.20 mm 0.014 – 0.047 in. Rear Sensor 0.40 – 1.20 mm 0.016 – 0.047 in. FRONT WHEEL SPEED SENSOR REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (2) Remove the tire and wheel assembly. (3) Remove the sensor cable routing clamp screws. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector (4) Remove speed sensor cable grommets from intermediate bracket on strut. (5) Disconnect speed sensor cable from vehicle wiring harness behind fender well shield. (6) Remove the wheel speed sensor head mounting bolt (Fig. 1). (7) Remove sensor head from steering knuckle. If sensor has seized due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side-to-side until free. (8) Remove front wheel speed sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown in this section may result in contact with moving parts and over extension of cables, resulting in an open circuit. 5 - 90 BRAKES - ABS RS FRONT WHEEL SPEED SENSOR (Continued) (2) Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips. Routing clips that are molded onto the brake hose will require replacement of the brake hose if damaged during removal or installation of the speed sensor cable. (3) Carefully remove speed sensor cable from press-in routing clips along brake hose and tubing. (4) Remove bolt securing wheel speed sensor cable metal clip to rear of axle. Remove metal clip from cable if necessary. Fig. 1 Front Wheel Speed Sensor Attaching Bolt 1 2 3 4 5 - MOUNTING BOLT WHEEL SPEED SENSOR DRIVESHAFT TONE WHEEL STEERING KNUCKLE (1) Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. (2) Install the bolts attaching the routing clamps to the body of the vehicle. Tighten the bolts to a torque of 14 N·m (125 in. lbs.). (3) Insert speed sensor cable grommets into intermediate bracket on strut. (4) Install the wheel speed sensor head mounting bolt (Fig. 1). Tighten the bolt to a torque of 13 N·m (115 in. lbs.) (5) Install the wheel and tire assembly on vehicle. (6) Lower vehicle. (7) Road test vehicle to ensure proper operation of the base and ABS brake systems. REAR WHEEL SPEED SENSOR - AWD REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) CAUTION: When disconnecting speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also, inspect connectors for any signs of previous damage. CAUTION: If speed sensor head has seized due to corrosion, do not use pliers on speed sensor head in an attempt to remove it. Use a hammer and a punch and tap mounting flange edge side-to-side, rocking the sensor until free. (5) Remove wheel speed sensor head attaching bolt. (6) Remove wheel speed sensor head from the axle, and remove sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as indicated may result in contact with moving parts or over-extension of cables, resulting in an open circuit. (1) Install wheel speed sensor head in axle flange. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. (2) Install wheel speed sensor head attaching bolt. Tighten bolt to a torque 10 N·m (90 in. lbs.). (3) Check the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. (Refer to 5 - BRAKES - SPECIFICATIONS) CAUTION: When installing wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake hose if damaged. (4) Install speed sensor cable under leaf spring onto brake hose and tubing utilizing routing clips to secure it in place. BRAKES - ABS RS 5 - 91 REAR WHEEL SPEED SENSOR - AWD (Continued) (5) Install metal routing clip on speed sensor cable and mount it to rear of axle with mounting bolt. Tighten mounting bolt to 16 N·m (140 in. lbs.). (6) Connect wheel speed sensor cable to vehicle wiring harness.Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. (7) Install speed sensor cable grommet into the floor pan, being sure the grommet is fully seated into the access hole. (8) Lower vehicle. (9) Road test vehicle to ensure proper operation of the base and ABS braking systems. the brake hose will require replacement of the brake hose if damaged during removal or installation of the speed sensor cable. (3) Carefully remove speed sensor cable from press-in routing clips (Fig. 3). REAR WHEEL SPEED SENSOR - FWD REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) CAUTION: When disconnecting speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also, inspect connectors for any signs of previous damage. (2) Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness (Fig. 2). Fig. 3 SPEED SENSOR CABLE ROUTING 1 - METAL CLIP AND MOUNTING BOLT 2 - ROUTING CLIPS (4) Remove bolt securing metal routing clip to rear of axle and remove sensor cable from metal clip (Fig. 3). (5) Remove secondary (yellow) retaining clip at rear of wheel speed sensor head (Fig. 4). (6) Push up on metal retaining clip (Fig. 4) until it bottoms. This will release wheel speed sensor head from hub and bearing. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. (7) Remove wheel speed sensor assembly from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cable is critical to continued system operation. Be sure that cable is installed in routing retainers/ clips. Failure to install cable in retainers may result in contact with moving parts or over extension of cable, resulting in an open circuit. Fig. 2 Wheel Speed Sensor Connector 1 - CONNECTOR 2 - FLOOR PAN 3 - GROMMET CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips. Routing clips that are molded onto NOTE: Make sure wheel speed sensor stays clean and dry as it is installed into the hub and bearing cap. (1) If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. 5 - 92 BRAKES - ABS RS REAR WHEEL SPEED SENSOR - FWD (Continued) Fig. 4 SENSOR CONNECTION AT HUB AND BEARING 1 - SECONDARY SENSOR RETAINING CLIP 2 - METAL SENSOR RETAINING CLIP 3 - HUB AND BEARING (2) Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. (3) Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. (4) Route sensor cable under leaf spring along rear of axle. Install speed sensor cable into routing clips on rear brake flex hose (Fig. 3). (5) Install cable into metal routing clip and attach it to the rear axle with mounting bolt (Fig. 3). Tighten mounting bolt to 16 N·m (140 in. lbs.). (6) Connect wheel speed sensor cable to vehicle wiring harness (Fig. 2). Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. (7) Install speed sensor cable grommet into hole in floor pan making sure grommet is fully seated into hole. (8) Lower vehicle. (9) Road test vehicle to ensure proper operation of the base and ABS braking systems. TONE WHEEL INSPECTION - TONE WHEEL NOTE: Rear tone wheels for front-wheel-drive vehicles are sealed within the hub and bearing assembly and cannot be inspected or replaced. Replacement of the hub and bearing is necessary. Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. • missing, chipped, or broken teeth • contact with the wheel speed sensor • wheel speed sensor to tone wheel alignment • wheel speed sensor to tone wheel clearance • excessive tone wheel runout • tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. (Refer to 3 DIFFERENTIAL & DRIVELINE/HALF SHAFT REMOVAL) If a rear tone wheel is found to need replacement on an all-wheel-drive model, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. (Refer to 5 - BRAKES - ABS/ELECTRICAL - SPECIFICATIONS) Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. Refer to SPECIFICATIONS in this section of the service manual for the maximum allowed tone wheel runout (Refer to 5 BRAKES - ABS/ELECTRICAL - SPECIFICATIONS). If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of the front driveshaft, rear driveshaft (AWD only) or rear hub and bearing is necessary. TRACTION CONTROL SWITCH DIAGNOSIS AND TESTING - TRACTION CONTROL SWITCH (1) Remove lower column shroud. (2) Disconnect traction control switch harness from column harness below column. (3) Using an ohmmeter, check for continuity reading between pins. Refer to TRACTION CONTROL SWITCH CONTINUITY test table and (Fig. 5). BRAKES - ABS RS 5 - 93 TRACTION CONTROL SWITCH (Continued) HYDRAULIC/MECHANICAL OPERATION - HYDRAULIC CIRCUITS AND VALVES Fig. 5 TRACTION CONTROL SWITCH CONNECTOR TRACTION CONTROL SWITCH CONTINUITY SWITCH POSITION CONTINUITY BETWEEN ACTUATED PINS 1 AND 2 ILLUMINATION PINS 1 AND 3 The hydraulic fluid control valves control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking. The following paragraphs explain how this works. For purposes of explanation only, it is assumed that only the right front wheel is experiencing antilock braking; the following diagrams show only the right front wheel in an antilock braking operation. NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION The hydraulic diagram (Fig. 6) shows the vehicle in the normal braking mode of the base brake hydraulic system. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. Fig. 6 Normal Braking Hydraulic Circuit 1 2 3 4 5 6 - OUTLET VALVE PUMP PISTON PUMP MOTOR (OFF) LOW PRESSURE ACCUMULATOR NORMALLY CLOSED VALVE (OFF) TO RIGHT FRONT WHEEL 7 - NORMALLY OPEN VALVE (OFF) 8 - MASTER CYLINDER PRESSURE 9 - FROM MASTER CYLINDER 10 - NOISE DAMPER CHAMBER 5 - 94 BRAKES - ABS RS HYDRAULIC/MECHANICAL (Continued) ABS PRIMARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) The hydraulic diagram (Fig. 7) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. • The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. • The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. • The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. Fig. 7 ABS Without Traction Control - Primary Hydraulic Circuit 1 2 3 4 5 6 7 - OUTLET VALVE PUMP PISTON PUMP MOTOR (ON) LOW PRESSURE ACCUMULATOR PRESSURE LOW PRESSURE ACCUMULATOR NORMALLY CLOSED VALVE (MODULATING) TO RIGHT FRONT WHEEL 8 - NORMALLY OPEN VALVE (MODULATING) 9 - FROM MASTER CYLINDER 10 - MASTER CYLINDER PRESSURE 11 - CONTROLLED WHEEL PRESSURE 12 - PUMP INTERSTAGE PRESSURE 13 - NOISE DAMPER CHAMBER BRAKES - ABS RS HYDRAULIC/MECHANICAL (Continued) ABS SECONDARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) The hydraulic diagram (Fig. 8) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. • The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. • The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. • The brake fluid will then be routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. • In the secondary circuit, 1.2 cc brake fluid is taken in by the lip seal saver to protect the lip seals on the master cylinder piston. Fig. 8 ABS Without Traction Control - Secondary Hydraulic Circuit 1 2 3 4 5 - OUTLET VALVE PUMP PISTON LOW PRESSURE ACCUMULATOR PRESSURE TO RIGHT FRONT WHEEL FROM MASTER CYLINDER 6 7 8 9 - MASTER CYLINDER PRESSURE CONTROLLED WHEEL PRESSURE PUMP INTERSTAGE PRESSURE LIP SEAL SAVER (SECONDARY CIRCUIT ONLY) 5 - 95 5 - 96 BRAKES - ABS RS HYDRAULIC/MECHANICAL (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 9) shows a vehicle with traction control in the normal braking mode. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. the hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump/motor. Fig. 9 ABS With Traction Control - Normal Braking Hydraulic Circuit 1 2 3 4 5 6 7 - OUTLET VALVE PUMP PISTON PUMP MOTOR (OFF) SUCTION VALVE LOW PRESSURE ACCUMULATOR NORMALLY CLOSED VALVE (OFF) TO RIGHT FRONT WHEEL 8 - NORMALLY OPEN VALVE (OFF) 9 - NORMALLY OPEN ASR VALVE (OFF) 10 - FROM MASTER CYLINDER 11 - HYDRAULIC SHUTTLE VALVE 12 - MASTER CYLINDER PRESSURE 13 - NOISE DAMPER CHAMBER BRAKES - ABS RS 5 - 97 HYDRAULIC/MECHANICAL (Continued) ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 10) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. • The hydraulic shuttle valve closes upon brake application so that the pump/motor cannot siphon brake fluid from the master cylinder. • The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. • The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. • The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. Fig. 10 ABS With Traction Control - ABS Braking Hydraulic Circuit 1 2 3 4 5 6 7 8 9 - OUTLET VALVE PUMP PISTON PUMP MOTOR (ON) SUCTION VALVE LOW PRESSURE ACCUMULATOR NORMALLY CLOSED VALVE (MODULATING) TO RIGHT FRONT WHEEL NORMALLY OPEN VALVE (MODULATING) NORMALLY OPEN ASR VALVE (OFF) 10 - FROM MASTER CYLINDER 11 - HYDRAULIC SHUTTLE VALVE 12 - MASTER CYLINDER PRESSURE 13 - CONTROLLED WHEEL PRESSURE 14 - LOW PRESSURE ACCUMULATOR PRESSURE 15 - PUMP INTERSTAGE PRESSURE 16 - NOISE DAMPER CHAMBER 5 - 98 BRAKES - ABS RS HYDRAULIC/MECHANICAL (Continued) ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 11) shows the vehicle in the ABS braking mode. The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed. • The normally open ASR valve is energized to isolate the brake fluid being pumped from the master cylinder and to isolate the driven wheel. • The normally open ASR valve bypasses the pump output back to the master cylinder at a fixed pressure setting. • The normally open and normally closed valves modulate (build/decay) the brake pressure as required to the spinning wheel. Fig. 11 Traction Control Hydraulic Circuit 1 2 3 4 5 6 7 8 9 - OUTLET VALVE PUMP PISTON PUMP MOTOR (ON) LOW PRESSURE ACCUMULATOR PRESSURE LOW PRESSURE ACCUMULATOR NORMALLY CLOSED VALVE (MODULATING) TO RIGHT FRONT WHEEL (SPINNING) NORMALLY OPEN VALVE (MODULATING) NORMALLY OPEN ASR VALVE ON (REGULATING) 10 - FROM MASTER CYLINDER 11 - HYDRAULIC SHUTTLE VALVE 12 - CONTROLLED WHEEL PRESSURE 13 - SUCTION VALVE 14 - PUMP INTERSTAGE PRESSURE 15 - NOISE DAMPER CHAMBER 16 - MASTER CYLINDER PRESSURE 17 - PUMP PRESSURE BRAKES - ABS RS HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION The hydraulic control unit (HCU) is mounted to the CAB as part of the ICU (Fig. 22). 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. The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is approximately 1 inch longer on the low pressure fluid accumulators side than a HCU on a vehicle that is equipped with only ABS. For more information, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) - DESCRIPTION) OPERATION For information on the operation of the HCU as a whole, refer to Hydraulic Circuits And Valve Operation which can be found elsewhere in this section. For information on the operation of the components within the HCU, refer to the following three topics. 5 - 99 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. For more information, refer to Traction Control System in this section. 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 5 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. On ABS-only vehicles, there is a mini-accumulator on the secondary hydraulic circuit that protects the master cylinder seals during an ABS stop, and there is a noise dampening chamber on the primary circuit. On ABS with traction control vehicles, there are two noise dampening chambers in the HCU. PUMP/MOTOR VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are springloaded 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. On vehicles with traction control, there is an extra set of valves and solenoids. The ASR valves, mounted in the HCU valve block, are normally in the open position and close only when the traction control is applied. These isolator valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic 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 CAB. 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, one piston draws fluid from the accumulators, and the opposing piston pumps fluid to the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The CAB 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. 5 - 100 BRAKES - ABS ICU (INTEGRATED CONTROL UNIT) DESCRIPTION The hydraulic control unit (HCU) and the controller antilock brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the integrated control unit (ICU) (Fig. 12). The ICU is located below the master cylinder in the engine compartment (Fig. 13). RS Two different ICU’s (HCU and CAB) are used on this vehicle depending on whether or not the vehicle is equipped with traction control. The HCU on a vehicle equipped with traction control has a valve block that is approximately one inch longer than a HCU on a vehicle that is equipped with ABS only. The ABS-only ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve block, fluid accumulators, a pump, and an electric motor. The ABS-with traction control ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), two traction control (ASR) valves, two hydraulic shuttle valves, valve block, fluid accumulators, a pump, and an electric motor. The replaceable components of the ICU are the HCU and the CAB. No attempt should be made to service any individual components of the HCU or CAB. For information on the CAB, (Refer to 8 ELECTRICAL/ELECTRONIC CONTROL MODULES/CONTROLLER ANTILOCK BRAKE DESCRIPTION). OPERATION Fig. 12 INTEGRATED CONTROL UNIT (ICU) 1 2 3 4 - PUMP/MOTOR HCU PUMP/MOTOR CONNECTOR CAB For information of the ICU, refer to these individual components of the ICU: • CONTROLLER ANTILOCK BRAKE (CAB) (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/CONTROLLER ANTILOCK BRAKE - OPERATION) • HYDRAULIC CONTROL UNIT (HCU) (Refer to 5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/ HCU (HYDRAULIC CONTROL UNIT) - OPERATION) For information on the ICU’s hydraulic circuits, refer to HYDRAULIC CIRCUITS AND VALVE OPERATION. (Refer to 5 - BRAKES - ABS/HYDRAULIC/MECHANICAL - OPERATION) REMOVAL REMOVAL - LHD Fig. 13 ICU LOCATION IN VEHICLE 1 - POWER BRAKE BOOSTER 2 - MASTER CYLINDER 3 - ICU (1) Disconnect the negative (ground) cable from the battery and isolate cable. (2) Remove the battery shield. (3) Remove the battery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL). (4) Disconnect the vacuum hose connector at the tank built into the battery tray. (5) Remove the screw securing the engine coolant filler neck to the battery tray. (6) Remove the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - REMOVAL). BRAKES - ABS RS 5 - 101 ICU (INTEGRATED CONTROL UNIT) (Continued) (7) Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder once the brake tubes are removed from the HCU. (16) Remove the pinch bolt and disconnect the steering shaft coupling. (17) Remove the two clips securing silencer to dash seal (Fig. 15). CAUTION: Do not apply a 12–volt power source to any terminals of the 24-way CAB connector when disconnected. (8) Disconnect the wiring harness connector from the speed control servo. (9) Remove the speed control servo mounting nuts and move the servo out of the way. (10) Disconnect the 24–way connector from the CAB. To disconnect the 24–way connector, grasp the lock on the 24–way connector and pull it as far up as possible. This will unlock the 24–way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes. (11) Thoroughly clean all surfaces of the ICU and brake tube nuts. Use only a solvent such as Mopart Brake Parts Cleaner or equivalent to clean the ICU. (12) Remove the brake tubes (4) from the outlet ports on the HCU (Fig. 14). Fig. 15 LOWER COUPLING AND DASH SEAL 1 2 3 4 5 6 - COUPLING DASH SEAL SILENCER MOUNTING SCREWS RETAINING CLIPS DASH (18) Remove the three screws securing the dash seal (Fig. 15). (19) Remove the 3 bolts attaching the ICU to its mounting bracket (Fig. 16). (20) Remove ICU from the vehicle through engine compartment. (21) If required, to separating the CAB from the HCU, (Refer to 5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) DISASSEMBLY). Fig. 14 BRAKE TUBE NUTS AT ICU 1 - PRIMARY BRAKE TUBE 2 - SECONDARY BRAKE TUBE 3 - CHASSIS BRAKE TUBES (13) Remove the primary and secondary brake tubes from the inlet ports on the HCU (Fig. 14). (14) Center and prop the steering wheel. (15) Remove the silencer panel under the instrument panel, below the steering column. REMOVAL - RHD NOTE: Before proceeding, (Refer to 5 - BRAKES WARNING)(Refer to 5 - BRAKES - CAUTION) (1) Disconnect the negative (ground) cable from the battery and isolate cable. (2) Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from 5 - 102 BRAKES - ABS RS ICU (INTEGRATED CONTROL UNIT) (Continued) Fig. 17 CAB 24-Way Connector Fig. 16 ICU MOUNTING BOLTS 1 - ICU MOUNTING BOLTS 2 - COUPLER draining out of the master cylinder when the brake tubes are removed from the HCU. (3) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Remove the routing clip attaching the ICU wiring harness to the ICU mounting bracket (Fig. 17). 1 2 3 4 5 6 7 - CAB WIRING HARNESS 24–WAY CONNECTOR FLOOR PAN HCU CAB HCU MOUNTING BRACKET CONNECTOR LOCK CAUTION: Do not apply a 12 volt power source to any terminals of the HCU connector when disconnected. (5) Remove the 24-way connector (Fig. 17) from the CAB. The 24-way connector is removed from the CAB using the following procedure. Grasp the lock on the 24-way connector (Fig. 17) and pull it as far out as possible (Fig. 18). This will raise and unlock the 24-way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes. (6) Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. Fig. 18 Unlocked 24-Way CAB Connector 1 2 3 4 - HCU CAB 24–WAY CONNECTOR CONNECTOR LOCK (UNLOCKED) BRAKES - ABS RS 5 - 103 ICU (INTEGRATED CONTROL UNIT) (Continued) (7) Remove the brake tubes (6) from the inlet and outlet ports on the HCU. (Fig. 19). (9) Remove ICU and the mounting bracket as a unit from the vehicle. (10) Remove the 3 bolts (Fig. 21) mounting the ICU to the mounting bracket. Separate the ICU from the mounting bracket. Fig. 19 Brake Tube Connections To HCU 1 2 3 4 5 6 7 8 9 - LEFT REAR WHEEL BRAKE TUBE SECONDARY BRAKE TUBE FROM MASTER CYLINDER LEFT FRONT WHEEL BRAKE TUBE CAB RIGHT REAR WHEEL BRAKE TUBE HCU MOUNTING BRACKET BRAKE TUBE TO HCU CONNECTION LOCATION LEGEND RIGHT FRONT WHEEL BRAKE TUBE PRIMARY BRAKE TUBE FROM MASTER CYLINDER (8) Remove the 3 bolts (Fig. 20) attaching the ICU mounting bracket to the front suspension crossmember. Fig. 21 ICU Mounting Bolts 1 - HCU 2 - HCU MOUNTING BOLTS 3 - HCU MOUNTING BRACKET (11) For the procedure on separating and attaching the CAB to the HCU, refer to DISASSEMBLY. DISASSEMBLY - ICU (1) Remove the ICU from the vehicle. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) - REMOVAL) (2) Disconnect the pump/motor wiring harness from the CAB (Fig. 22). (3) Remove the 4 bolts (Fig. 23) attaching the CAB to the HCU. (4) Remove the CAB from the HCU (Fig. 24). ASSEMBLY - ICU Fig. 20 ICU To Suspension Cradle Mounting Bolts 1 2 3 4 5 - HCU MOUNTING BRACKET BOLTS HCU MOUNTING BRACKET BOLT CAB HCU MOUNTING BRACKET HCU (1) Install the CAB (Fig. 24) on the HCU. (2) Install the 4 bolts mounting the CAB (Fig. 23) to the HCU. Tighten the CAB mounting bolts to a torque of 2 N·m (17 in. lbs.). (3) Plug the pump/motor wiring harness into the CAB. (4) Install the ICU in the vehicle and bleed the base and ABS hydraulic systems. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) - INSTALLATION) 5 - 104 BRAKES - ABS RS ICU (INTEGRATED CONTROL UNIT) (Continued) Fig. 22 INTEGRATED CONTROL UNIT (ICU) 1 2 3 4 - PUMP/MOTOR HCU PUMP/MOTOR CONNECTOR CAB Fig. 24 (TYPICAL) Remove/Install CAB 1 - CAB 2 - HCU VALVES 3 - HCU VALVE BLOCK (4) Install the silencer on top of the dash seal (Fig. 15). (5) Connect the steering shaft coupling and install the pinch bolt (Fig. 15). Tighten the pinch bolt to 28 N·m (250 in. lbs.). (6) Install the silencer panel below the steering column under the instrument panel. (7) Remove the steering wheel holder. CAUTION: Because of the flexible section in the primary and secondary brake tubes, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. Fig. 23 (TYPICAL) CAB Attaching Bolts 1 - MOUNTING BOLTS 2 - CAB 3 - HCU VALVE BLOCK INSTALLATION INSTALLATION - LHD (1) Place the ICU in its bracket below the master cylinder. Start the upper mounting bolt to hold it in place. (2) Inside the vehicle, install the remaining 2 mounting bolts attaching the ICU to the mounting bracket (Fig. 16). Tighten all 3 mounting bolts to a torque of 11 N·m (97 in. lbs.). (3) Install the dash seal and three mounting screws (Fig. 15). (8) Install the primary and secondary brake tubes into their correct port locations on the HCU valve block (Fig. 14). Tighten the tube nuts to a torque of 17 N·m (145 in. lbs.). CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the CAB. (9) Install the (4) chassis brake tubes into their correct port locations on the HCU valve block as shown (Fig. 14). Tighten the tube nuts to a torque of 17 N·m (145 in. lbs.). BRAKES - ABS RS 5 - 105 ICU (INTEGRATED CONTROL UNIT) (Continued) NOTE: Before installing the 24–way connector in the CAB be sure the seal is properly installed in the connector. (10) Install the 24–way connector on the CAB by, first, positioning the 24–way connector in the socket of the CAB and carefully pushing it down as far as possible. Once connector is fully seated by hand into the CAB socket, push down on connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. (11) Install any routing clips on the brake tubes. (12) Remove the brake pedal holder. (13) Install the speed control servo with its mounting nuts. (14) Connect the wiring harness to the speed control servo. (15) Install the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - INSTALLATION). (16) Install the screw securing the coolant filler neck to the battery tray. (17) Reconnect the vacuum hose connector at the tank built into the battery tray. (18) Install the battery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION). (19) Install the battery shield. (20) Remove the brake pedal holder. (21) Connect negative cable back on negative post of the battery. (22) Bleed the Base and ABS brake hydraulic systems (Refer to 5 - BRAKES - STANDARD PROCEDURE). (23) Road test vehicle to ensure proper operation of the base and antilock brake systems. INSTALLATION - RHD (1) Install the ICU on the mounting bracket (Fig. 21). Install the 3 bolts (Fig. 21) attaching the ICU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 N·m (97 in. lbs.). CAUTION: The ICU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the ICU bracket to the front suspension crossmember. (2) Install the ICU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the ICU bracket to the crossmember (Fig. 20). Tighten the 3 mounting bolts to a torque of 28 N·m (250 in. lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to (Fig. 19) for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the ICU mounting bracket. (3) Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown in (Fig. 19). Tighten the tube nuts to a torque of 17 N·m (145 in. lbs.). NOTE: Before installing the 24-way connector in the CAB be sure the seal is properly installed in the connector. (4) Install the 24-way connector (Fig. 17) on the CAB using the following procedure. Position the 24-way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock (Fig. 18). This will pull the connector into the socket of the CAB and lock it in the installed position. NOTE: The CAB wiring harness must be clipped to the ICU mounting bracket. This will ensure the wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle. 5 - 106 BRAKES - ABS RS ICU (INTEGRATED CONTROL UNIT) (Continued) (5) Clip the cab wiring harness (Fig. 17) to the ICU mounting bracket. (6) Install the routing clips (Fig. 25) on the brake tubes. (7) Lower the vehicle. (8) Connect negative cable back on negative post of the battery. (9) Bleed the base and ABS hydraulic systems. (Refer to 5 - BRAKES - STANDARD PROCEDURE) (10) Road test vehicle to ensure proper operation of the base and antilock brake systems. Fig. 25 Brake Tube Routing Clips 1 2 3 4 - ROUTING CLIP HCU BRAKE TUBES ROUTING CLIP WIRING RS 8W - 1 WIRING TABLE OF CONTENTS page WIRING DIAGRAM INFORMATION. . . . . . . COMPONENT INDEX . . . . . . . . . . . . . . . . . . POWER DISTRIBUTION . . . . . . . . . . . . . . . GROUND DISTRIBUTION . . . . . . . . . . . . . . BUS COMMUNICATIONS . . . . . . . . . . . . . . CHARGING SYSTEM . . . . . . . . . . . . . . . . . . STARTING SYSTEM . . . . . . . . . . . . . . . . . . FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . TRANSMISSION CONTROL SYSTEM . . . . . VEHICLE SPEED CONTROL . . . . . . . . . . . . ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . VEHICLE THEFT SECURITY SYSTEM . . . . . INSTRUMENT CLUSTER . . . . . . . . . . . . . . . HORN/CIGAR LIGHTER/POWER OUTLET . . AIR CONDITIONING-HEATER . . . . . . . . . . . AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . BODY CONTROL MODULE . . . . . . . . . . . . . 8W-01-1 8W-02-1 8W-10-1 8W-15-1 8W-18-1 8W-20-1 8W-21-1 8W-30-1 8W-31-1 8W-33-1 8W-35-1 8W-39-1 8W-40-1 8W-41-1 8W-42-1 8W-43-1 8W-44-1 8W-45-1 page MESSAGE CENTER . . . . . . . . . . . . . . . . . . . AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . REAR WINDOW DEFOGGER. . . . . . . . . . . . OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . POWER WINDOWS. . . . . . . . . . . . . . . . . . . POWER DOOR LOCKS . . . . . . . . . . . . . . . . POWER MIRRORS . . . . . . . . . . . . . . . . . . . POWER SEATS . . . . . . . . . . . . . . . . . . . . . . SPLICE INFORMATION . . . . . . . . . . . . . . . . CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . CONNECTOR/GROUND/SPLICE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . POWER DISTRIBUTION SYSTEM . . . . . . . . 8W-46-1 8W-47-1 8W-48-1 8W-49-1 8W-50-1 8W-51-1 8W-52-1 8W-53-1 8W-54-1 8W-60-1 8W-61-1 8W-62-1 8W-63-1 8W-70-1 8W-80-1 8W-91-1 8W-97-1 RS 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page WIRING DIAGRAM INFORMATION DESCRIPTION DESCRIPTION - HOW TO USE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - CIRCUIT INFORMATION . DESCRIPTION - CIRCUIT FUNCTIONS . . . DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION . . . . . . . . . . . . . . . . . DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION . . . . . . . . . . . WARNING WARNINGS - GENERAL . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES . . . . . . . . . . . . . . . . STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL . . . . . . . . . . . . . . . . STANDARD PROCEDURE - TESTING FOR CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . ...1 ...5 ...6 ...6 ...7 ...7 ...7 ...8 ...9 page STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 9 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS . . . . . . . . . . . 10 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . 10 SPECIAL TOOLS WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . 10 CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIODE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 TERMINAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 WIRE STANDARD PROCEDURE - WIRE SPLICING . . 15 ...9 WIRING DIAGRAM INFORMATION DESCRIPTION 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 (Fig. 1). All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). 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. SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1 RS RS 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2 8W - 01 - 3 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS RS 8W-01 WIRING DIAGRAM INFORMATION RS 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WIRE COLOR CODE CHART 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 Built-Up-Export . . . . . . . . Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export . . Vehicles Built For Sale In North America DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). Fig. 4 WIRE CODE IDENTIFICATION 1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER 2 - GAGE OF WIRE (18 GAGE) 3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON EQUIPMENT) 4 - MAIN CIRCUIT IDENTIFICATION COLOR CODE COLOR BL BLUE BK BLACK BR BROWN DB DARK BLUE DG DARK GREEN GY GRAY LB LIGHT BLUE LG LIGHT GREEN OR ORANGE PK PINK RD RED TN TAN VT VIOLET WT WHITE YL YELLOW * WITH TRACER 8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION RS WIRING DIAGRAM INFORMATION (Continued) 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 IDENTIFICATION CODE CHART CIRCUIT FUNCTION 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 Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. A BATTERY FEED B BRAKE CONTROLS C CLIMATE CONTROLS D DIAGNOSTIC CIRCUITS E DIMMING ILLUMINATION CIRCUITS F FUSED CIRCUITS G MONITORING CIRCUITS (GAUGES) H OPEN I NOT USED J OPEN 8W-01 thru 8W-09 General information and Diagram Overview K POWERTRAIN CONTROL MODULE 8W-10 thru 8W-19 Main Sources of Power and Vehicle Grounding L EXTERIOR LIGHTING Starting and Charging M INTERIOR LIGHTING 8W-20 thru 8W-29 N NOT USED Powertrain/Drivetrain Systems O NOT USED 8W-30 thru 8W-39 P POWER OPTION (BATTERY FEED) 8W-40 thru 8W-49 Body Electrical items and A/C Q POWER OPTIONS (IGNITION FEED) 8W-50 thru 8W-59 Exterior Lighting, Wipers and Trailer Tow R PASSIVE RESTRAINT 8W-60 thru 8W-69 Power Accessories S SUSPENSION/STEERING 8W-70 Splice Information T TRANSMISSION/TRANSAXLE/ TRANSFER CASE 8W-80 Connector Pin Outs 8W-91 Connector, Ground and Splice Locations U OPEN V SPEED CONTROL, WIPER/ WASHER W OPEN X AUDIO SYSTEMS Y OPEN Z GROUNDS WIRING SECTION CHART GROUP TOPIC RS 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) 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. • Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. 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 WARNING 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. 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. 8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION RS WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today’s vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle’s electrical system can cause damage to the equipment and provide false readings. • Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. are listed and explained below. Always check for nonfactory 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. STANDARD PROCEDURE STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES Fig. 5 PROBING TOOL 1 - SPECIAL TOOL 6801 2 - PROBING END 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 All ESD sensitive components are solid state and a symbol (Fig. 6) 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 form it’s protective packing until it is time to install the part. (5) Before removing the part from it’s pakage, ground the pakage to a known good ground on the vehicle. TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL RS 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 7). (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. Fig. 8 TESTING FOR CONTINUITY 1 - FUSE REMOVED FROM CIRCUIT STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND Fig. 7 TESTING FOR VOLTAGE POTENTIAL STANDARD PROCEDURE - TESTING FOR CONTINUITY (1) Remove the fuse for the circuit being checked or, disconnect the battery. (2) Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). (3) Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. (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. 8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION RS WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS SPECIAL TOOLS WIRING/TERMINAL (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. STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP PROBING TOOL PACKAGE 6807 (1) Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). (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. TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 Fig. 9 TESTING FOR VOLTAGE DROP TERMINAL REMOVING TOOL 6934 8W-01 WIRING DIAGRAM INFORMATION RS CONNECTOR REMOVAL (1) Disconnect battery. (2) Release Connector Lock (Fig. 10). (3) Disconnect the connector being repaired from its mating half/component. (4) Remove the dress cover (if applicable) (Fig. 10). Fig. 10 REMOVAL OF DRESS COVER 1 - DRESS COVER 2 - CONNECTOR LOCK 3 - CONNECTOR (5) Release the Secondary Terminal Lock, if required (Fig. 11). (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 (Fig. 12). 8W - 01 - 11 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. 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock RS RS 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 2 3 4 5 6 7 - TYPICAL CONNECTOR - PICK FROM SPECIAL TOOL KIT 6680 - APEX CONNECTOR - PICK FROM SPECIAL TOOL KIT 6680 - AUGAT CONNECTOR - SPECIAL TOOL 6932 - MOLEX CONNECTOR 8 - SPECIAL TOOL 6742 9 - THOMAS AND BETTS CONNECTOR 10 - SPECIAL TOOL 6934 11 - TYCO CONNECTOR 12 - SPECIAL TOOL 8638 8W - 01 - 13 8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION RS DIODE TERMINAL 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 (Fig. 13). (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 Fig. 13 DIODE IDENTIFICATION 1 - CURRENT FLOW 2 - BAND AROUND DIODE INDICATES CURRENT FLOW 3 - DIODE AS SHOWN IN THE DIAGRAMS INSTALLATION (1) Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. (2) Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). (3) Solder the connection together using rosin core type solder only. Do not use acid core solder. (4) Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. (5) Re-connect the battery and test affected systems. (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. (7) Connect battery and test all affected systems. 8W-01 WIRING DIAGRAM INFORMATION RS 8W - 01 - 15 (5) Solder the connection together using rosin core type solder only (Fig. 16). WIRE 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 (Fig. 14). CAUTION: DO NOT USE ACID CORE SOLDER. Fig. 16 SOLDER SPLICE 1 - SOLDER 2 - SPLICE BAND 3 - SOLDERING IRON (6) Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Fig. 14 SPLICE BAND 1 - SPLICE BAND (4) Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 17 HEAT SHRINK TUBE 1 - SEALANT 2 - HEAT SHRINK TUBE Fig. 15 CRIMPING TOOL 1 - CRIMPING TOOL RS 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page A/C Compressor Clutch Relay . . . . . . . . . . . . 8W-42 A/C Compressor Clutch . . . . . . . . . . . . . . . . . 8W-42 A/C- Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42 A/C Pressure Sensor . . . . . . . . . . . . . . . . . . . 8W-42 A/C-Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42 Accelerator Pedal Position Sensor . . . . . . . . . 8W-30 Accessory Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-10 Adjustable Pedals Module . . . . . . . . . . . . . . . 8W-30 Adjustable Pedals Switch . . . . . . . . . . . . . . . . 8W-30 Airbag Control Module . . . . . . . . . . . . . . . . . . 8W-43 Ambient Temp Sensor . . . . . . . . . . . . . . . . . . 8W-49 Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Auto Shut Down Relay . . . . . . . . . . . . . . . . . 8W-30 Auto Temp Control . . . . . . . . . . . . . . . . . . . . . 8W-42 Automatic Day/Night Mirror . . . . . . . . . . . . . 8W-49 Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . 8W-51 Battery Temperature Sensor . . . . . . . . . . . . . 8W-20 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20 Blend Door Actuators . . . . . . . . . . . . . . . . . . . 8W-42 Body Control Module . . . . . . . . . . . . . . . . . . . 8W-45 Boost Pressure Sensor . . . . . . . . . . . . . . . . . . 8W-30 B-Pillar Switches . . . . . . . . . . . . . . . . . . . . . . 8W-61 Brake Lamp Switch . . . . . . . . . . . . . . . . . 8W-30, 51 Brake Transmission Shift Interlock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31 Cabin Heater Assist . . . . . . . . . . . . . . . . . . . . 8W-30 Camshaft Position Sensor . . . . . . . . . . . . . . . 8W-30 CD Changer . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Center High Mounted Stop Lamp . . . . . . . . . 8W-51 Cinch/Release Motors . . . . . . . . . . . . . . . . . . . 8W-61 Clockspring . . . . . . . . . . . . . . . . . . 8W-33, 41, 43, 47 Clutch Pedal Interlock Switch Jumper . . . . . 8W-10 Clutch Pedal Interlock Switch . . . . . . . . . . . . 8W-10 Combination Relays . . . . . . . . . . . . . . . . . . . . 8W-54 Controller Antilock Brake . . . . . . . . . . . . . . . 8W-35 Crank Case Ventilation Heater . . . . . . . . . . . 8W-30 Crankshaft Position Sensor . . . . . . . . . . . . . . 8W-30 Cylinder Lock Switches . . . . . . . . . . . . . . . . . 8W-39 Data Link Connector . . . . . . . . . . . . . . . . . . . 8W-18 Diagnostic Junction Port . . . . . . . . . . . . . . . . 8W-18 Door Ajar Switches . . . . . . . . . . . . . . . . . . . . 8W-39 Door Lock Motor/Ajar Switches . . . . . . . . . . . 8W-61 Door Lock Switches . . . . . . . . . . . . . . . . . . . . 8W-61 Driver Airbag . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43 EGR Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Electric Wiper De-Icer . . . . . . . . . . . . . . . . . . 8W-48 Engine Control Module . . . . . . . . . . . . . . . . . 8W-30 Engine Coolant Temp Sensor . . . . . . . . . . . . . 8W-30 Engine Oil Pressure Switch . . . . . . . . . . . . . . 8W-30 EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . 8W-30 Evaporator Temperature Sensor . . . . . . . . . . 8W-42 Floor Console Lamp . . . . . . . . . . . . . . . . . . . . 8W-44 Component Page Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50 Front Blower Module . . . . . . . . . . . . . . . . . . . 8W-42 Front Blower Motor Relay . . . . . . . . . . . . . . . 8W-42 Front Blower Motor . . . . . . . . . . . . . . . . . . . . 8W-42 Front Cigar Lighter . . . . . . . . . . . . . . . . . . . . 8W-41 Front Control Module . . . . . . . . . . . . . . . . . . 8W-10 Front Fog Lamp Relay . . . . . . . . . . . . . . . . . . 8W-50 Front Intrusion Sensor . . . . . . . . . . . . . . . . . 8W-39 Front Washer Pump Motor . . . . . . . . . . . . . . 8W-53 Front Wiper On/Off Relay . . . . . . . . . . . . . . . 8W-53 Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Fuel Pressure Solenoid . . . . . . . . . . . . . . . . . 8W-30 Fuel Pump Module . . . . . . . . . . . . . . . . . . . . 8W-30 Full Open Switches . . . . . . . . . . . . . . . . . . . . 8W-61 Fuselink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20 Glow Plug Relay . . . . . . . . . . . . . . . . . . . . . . 8W-30 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15 Halo Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44 Headlamp Leveling Motors . . . . . . . . . . . . . . 8W-50 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . 8W-50 Headlamp Washer Relay . . . . . . . . . . . . . . . . 8W-53 Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50 Heated Seat Backs . . . . . . . . . . . . . . . . . . . . . 8W-63 Heated Seat Cushions . . . . . . . . . . . . . . . . . . 8W-63 Heated Seat Modules . . . . . . . . . . . . . . . . . . . 8W-63 High Beam Lamps . . . . . . . . . . . . . . . . . . . . . 8W-50 High Note Horn . . . . . . . . . . . . . . . . . . . . . . . 8W-41 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41 Idle Air Control Motor . . . . . . . . . . . . . . . . . . 8W-30 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-10 Inlet Air Temperature Sensor . . . . . . . . . . . . 8W-30 Instrument Cluster . . . . . . . . . . . . . . . . . . . . 8W-40 Instrument Panel Switch Bank . . 8W-44, 52, 53, 63 Integrated Power Module . . . . . . . . . . . . . . . . 8W-10 Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51 Lift Pump Motor . . . . . . . . . . . . . . . . . . . . . . 8W-30 Liftgate Ajar Switch . . . . . . . . . . . . . . . . . 8W-39, 61 Liftgate Cinch/Release Motor . . . . . . . . . . . . . 8W-61 Liftgate Cylinder Lock Switch . . . . . . . . . . . . 8W-39 Liftgate Flood Lamps . . . . . . . . . . . . . . . . . . . 8W-44 Liftgate Right Pinch Sensor . . . . . . . . . . . . . . 8W-61 Low Beam Lamps . . . . . . . . . . . . . . . . . . . . 8W-50-9 Manifold Absolute Pressure Sensor . . . . . . . . 8W-30 Mass Air Flow Sensor . . . . . . . . . . . . . . . . . . 8W-30 Memory Seat/Mirror Module . . . . . . . . . . 8W-62, 63 Memory Set Switch . . . . . . . . . . . . . . . . . . . . 8W-63 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Mid Reading Lamps . . . . . . . . . . . . . . . . . . . . 8W-44 Mode Door Actuator . . . . . . . . . . . . . . . . . . . . 8W-42 Multi- Function Switch . . . . . . . . . . . 8W-50, 52, 53 Output Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31 Overhead Console . . . . . . . . . . . . . . . . . . . . . 8W-49 Oxygen Sensor 1/1 Upstream . . . . . . . . . . . . . 8W-30 Oxygen Sensor 1/2 Downstream . . . . . . . . . . 8W-30 Park Lamp Relay . . . . . . . . . . . . . . . . . . . . . . 8W-10 Park Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50 Park/Turn Signal Lamps . . . . . . . . . . . . . . . . 8W-50 Parking Brake Switch . . . . . . . . . . . . . . . . . . 8W-40 Passenger Airbag . . . . . . . . . . . . . . . . . . . . . . 8W-43 Positive Temperature Coefficients . . . . . . . . . 8W-10 Power Liftgate Module . . . . . . . . . . . . . . . . . . 8W-61 Power Liftgate Motor . . . . . . . . . . . . . . . . . . . 8W-61 Power Mirror Switch . . . . . . . . . . . . . . . . . . . 8W-62 Power Mirrors . . . . . . . . . . . . . . . . . . . . . . . . 8W-62 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41 Power Seat Circuit Breaker . . . . . . . . . . . . . . 8W-10 Power Seat Front Riser Motors . . . . . . . . . . . 8W-63 Power Seat Horizontal Motors . . . . . . . . . . . . 8W-63 Power Seat Horizontal Position Sensors . . . . 8W-63 Power Seat Rear Riser Motors . . . . . . . . . . . . 8W-63 Power Seat Rear Riser Position Sensors . . . . 8W-63 Power Seat Recliner Motors . . . . . . . . . . . . . . 8W-63 Power Seat Switches . . . . . . . . . . . . . . . . . . . 8W-63 Power Window Circuit Breaker . . . . . . . . . . . 8W-10 Power Window Motors . . . . . . . . . . . . . . . . . . 8W-60 Power Window Switches . . . . . . . . . . . . . . . . 8W-60 Powertrain Control Module . . . . . . . . . . . . . . 8W-30 Radiator Fan Relays . . . . . . . . . . . . . . . . . . . 8W-42 Radiator Fans . . . . . . . . . . . . . . . . . . . . . . . . 8W-42 Radio Choke . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Reading Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-44 Rear A/C-Heater Unit . . . . . . . . . . . . . . . . . . 8W-42 Rear Auto Temp Control Switch . . . . . . . . . . . 8W-42 Rear Blower Front Control Switch . . . . . . . . . 8W-42 Rear Blower Motor Power Module . . . . . . . . . 8W-42 Rear Blower Motor Relay . . . . . . . . . . . . . . . . 8W-42 Rear Blower Motor . . . . . . . . . . . . . . . . . . . . . 8W-42 Rear Blower Rear Control Switch . . . . . . . . . 8W-42 Rear Intrusion Sensor . . . . . . . . . . . . . . . . . . 8W-39 Component Rear Lamp Assemblies . . . . . . . . . . . . . Rear Mode Motor . . . . . . . . . . . . . . . . . Rear Power Outlet . . . . . . . . . . . . . . . . Rear Temperature Motor . . . . . . . . . . . Rear Washer Pump Motor . . . . . . . . . . Rear Window Defogger Grid . . . . . . . . Recirculation Door Actuator . . . . . . . . . Remote Keyless Entry Antenna . . . . . . Remote Radio Switches . . . . . . . . . . . . Repeater Lamps . . . . . . . . . . . . . . . . . . Seat Airbag . . . . . . . . . . . . . . . . . . . . . Seat Belt Tensioners . . . . . . . . . . . . . . Sentry Key Immobilizer Module . . . . . Side Impact Airbag Control Modules . . Siren . . . . . . . . . . . . . . . . . . . . . . . . . . Sliding Door Control Modules . . . . . . . Sliding Door Latch Sensing Switches . . Sliding Door Lock Motor/Ajar Switches Sliding Door Lock Motors . . . . . . . . . . Sliding Door Motors . . . . . . . . . . . . . . . Solenoid/Pressure Switch Assy . . . . . . . Speakers . . . . . . . . . . . . . . . . . . . . . . . Speed Control Servo . . . . . . . . . . . . . . Speed Control Switches . . . . . . . . . . . . Splice Information . . . . . . . . . . . . . . . . Starter Motor Relay . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . Stop/Turn Signal Relays . . . . . . . . . . . Thatcham Alarm Module . . . . . . . . . . . Throttle Position Sensor . . . . . . . . . . . Torque Converter Clutch Solenoid . . . . Traction Control Switch . . . . . . . . . . . . Trailer Tow Connector . . . . . . . . . . . . . Transmission Control Module . . . . . . . Transmission Range Sensor . . . . . . . . . Turn Signal Lamps . . . . . . . . . . . . . . . TXV Solenoid . . . . . . . . . . . . . . . . . . . . Vehicle Speed Sensor . . . . . . . . . . . . . . Vent Motors . . . . . . . . . . . . . . . . . . . . . Visor/Vanity Lamps . . . . . . . . . . . . . . . Washer Fluid Level Switch . . . . . . . . . Water In Fuel Sensor . . . . . . . . . . . . . . Wheel Speed Sensors . . . . . . . . . . . . . . RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8W-51 8W-42 8W-41 8W-42 8W-53 8W-48 8W-42 8W-61 8W-47 8W-52 8W-43 8W-43 8W-39 8W-43 8W-39 8W-61 8W-61 8W-61 8W-61 8W-61 8W-31 8W-47 8W-33 8W-33 8W-70 8W-21 8W-21 8W-54 8W-39 8W-30 8W-31 8W-35 8W-54 8W-31 8W-31 8W-52 8W-42 8W-30 8W-60 8W-44 8W-53 8W-30 8W-35 RS 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page A/C Compressor Clutch . . . . . . . 8W-10-22, 24, 45, 47 A/C Compressor Clutch Relay . . . . . . . . . . . . . . . . 8W-10-22, 24, 44, 45, 47 Accessory Relay . . . . . . . . . . . . . . . . 8W-10-16, 31, 64 Adjustable Pedals Module . . . . . . . . . . . 8W-10-40, 46 Airbag Control Module . . . . . . . . . . . . . 8W-10-63, 68 Ambient Temp Sensor . . . . . . . . . . . . . . . . . 8W-10-61 Auto Shut Down Relay . . . . . . . . . . . . . 8W-10-21, 41 Auto Temp Control . . . . . . . . . . . . . . . . . . . 8W-10-40 Back-Up Lamp Switch . . . . . . . . . . . . . . . . 8W-10-65 Battery . . . . . . . . . . . . . . . . . 8W-10-13, 14, 15, 41, 47 Blower Motor Resistor . . . . . . . . . . . . . . 8W-10-19, 38 Body Control Module . . . . . . 8W-10-25, 40, 45, 48, 49, 51, 53, 54, 55, 56, 68 Brake Fluid Level Switch . . . . . . . . . . . . . . 8W-10-64 Brake Lamp Switch . . . . . . . . . . . . . 8W-10-26, 51, 66 Brake Transmission Shift Interlock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-62 Cabin Heater Assist . . . . . . . . . . . . . 8W-10-23, 43, 59 Camshaft Position Sensor . . . . . . . . . . . . . . 8W-10-44 Center High Mounted Stop Lamp . . . . . . . . 8W-10-66 Clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-60 Clutch Pedal Interlock Switch . . . . . . . . . . . . . . . 8W-10-18, 37, 53, 54, 60 Clutch Pedal Interlock Switch Jumper . . . . . . . . . . . . . . . 8W-10-18, 37, 53, 54, 60 Controller Antilock Brake . . . . . . . . . . 8W-10-18, 25, 37, 49, 55, 61, 66 Crank Case Ventilation Heater . . . . . . . . . . 8W-10-48 Data Link Connector . . . . . . . . . . . . . . . 8W-10-36, 68 Defogger Relay . . . . . . . . . . . . . . 8W-10-19, 20, 39, 63 Diagnostic Junction Port . . . . . . . . . . . . . . . 8W-10-61 Driver Door Lock Switch . . . . . . . . . . . . 8W-10-33, 35 Driver Heated Seat Module . . . . . . . . . . . . . 8W-10-49 Driver Power Seat Switch . . . . . . . . . . . . . . 8W-10-49 Driver Power Window Switch . . . . . . . . 8W-10-34, 35 ECM/PCM Relay . . . . . . . . . . . . . . . . . . 8W-10-23, 43 EGR Solenoid . . . . . . . . . . . . . . . . . . . . 8W-10-44, 46 Electric Wiper De-Icer . . . . . . . . . . . . . . . . . 8W-10-33 Engine Control Module . . 8W-10-18, 23, 24, 37, 43, 44, 47, 48, 65, 66 Floor Console Lamp . . . . . . . . . . . . . . . . . . 8W-10-32 Floor Console Power Outlet . . . . . . . . . . 8W-10-32, 36 Front Blower Module . . . . . . . . . . . . . . . 8W-10-19, 38 Front Blower Motor Relay . . . . . 8W-10-18, 19, 38, 63 Front Cigar Lighter . . . . . . . . . . . . . . . . 8W-10-16, 32 Front Control Module . . . . . 8W-10-15, 16, 17, 18, 19, 20, 22, 24, 26, 27, 28, 29, 30, 31, 36, 37, 38, 39, 45, 47, 52, 53, 54, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 68 Front Fog Lamp Relay . . . . . . . . . . . 8W-10-15, 27, 63 Component Page Front Washer Pump Motor . . . . . . . . 8W-10-16, 31, 68 Front Wiper Hi/Low Relay . . . . . . . . 8W-10-16, 30, 64 Front Wiper On/Off Relay . . . . . . . . 8W-10-16, 30, 59 Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-48 Fuel Heater Relay . . . . . . . . . . . . . . 8W-10-24, 47, 64 Fuel Injector No. 1 . . . . . . . . . . . . . . . . . . . 8W-10-42 Fuel Injector No. 2 . . . . . . . . . . . . . . . . . . . 8W-10-42 Fuel Injector No. 3 . . . . . . . . . . . . . . . . . . . 8W-10-42 Fuel Injector No. 4 . . . . . . . . . . . . . . . . . . . 8W-10-42 Fuel Injector No. 5 . . . . . . . . . . . . . . . . . . . 8W-10-42 Fuel Injector No. 6 . . . . . . . . . . . . . . . . . . . 8W-10-42 Fuel Pressure Solenoid . . . . . . . . . . . . . . . . 8W-10-44 Fuel Pump Module . . . . . . . . . . . . . . . . 8W-10-22, 45 Fuel Pump Relay . . . . . . . . . . . . . . . 8W-10-22, 45, 64 Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16, 27 Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 28, 29 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 28, 29 Fuse 4 . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16, 17, 30 Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31 Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 36 Fuse 9 . . . . . . . . . . . . . . . . . . . . 8W-10-17, 18, 19, 37 Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 38 Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31 Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 38 Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 39 Fuse 14 . . . . . . . . . . . . . . . . 8W-10-20, 21, 23, 39, 59 Fuse 15 . . . . . . . . . . . 8W-10-20, 21, 22, 23, 24, 41, 43 Fuse 16 . . . . . . . . . . . . . . . . . . . 8W-10-21, 23, 41, 43 Fuse 17 . . . . . . . . . . . . . . 8W-10-21, 22, 23, 24, 45, 47 Fuse 18 . . . . . . . . . . . . . . . . 8W-10-22, 24, 25, 45, 47 Fuse 19 . . . . . . . . . . . . . . . . 8W-10-22, 24, 25, 26, 49 Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 49 Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 49 Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 49 Fuse 23 . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 53, 54 Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 51 Fuse 26 . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 26, 51 Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 51 Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31 Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 52 Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 52 Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 52 Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31 Fuselink . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-55 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41, 47 G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-68 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-57, 58 Generator . . . . . . . . . . . . . . . . . 8W-10-13, 14, 42, 44 Glow Plug Relay . . . . . . . . . . . . . . . . . . 8W-10-13, 44 Headlamp Switch . . . . . . . . . . . . . . . . . 8W-10-29, 62 8W - 10 - 2 8W-10 POWER DISTRIBUTION Component Page Headlamp Washer Pump Motor . . . . . . . 8W-10-26, 52 Headlamp Washer Relay . . . . . . . . . 8W-10-26, 52, 63 High Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-10-36 Horn Relay . . . . . . . . . . . . . . . . . . . 8W-10-17, 36, 59 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-42 Ignition Switch . . 8W-10-18, 25, 37, 45, 46, 48, 53, 54, 60 Instrument Cluster . . . . . . . . . . . . . . . . 8W-10-25, 51 Integrated Power Module . . . 8W-10-3, 4, 5, 13, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 68 Leak Detection Pump . . . . . . . . . . . . . . . . . 8W-10-46 Left B-Pillar Switch . . . . . . . . . . . . . . . . . . 8W-10-33 Left Combination Relay . . . . . . . . . . . . . . . 8W-10-67 Left Fog Lamp . . . . . . . . . . . . . . . . . . . 8W-10-15, 27 Left Front Park/Turn Signal Lamp . . . . . . . . . . . . . . . . . . . 8W-10-15, 28, 56, 65 Left Headlamp . . . . . . . . . . . . . . . . . . . . . . 8W-10-57 Left Headlamp Leveling Motor . . . . . 8W-10-29, 62, 65 Left High Beam Lamp . . . . . . . . . . . . . . . . 8W-10-58 Left Low Beam Lamp . . . . . . . . . . . . . . . . . 8W-10-58 Left Park Lamp . . . . . . . . . . . . . . . . . . . 8W-10-29, 65 Left Power Mirror . . . . . . . . . . . . . . . . . . . . 8W-10-39 Left Rear Lamp Assembly . . . 8W-10-28, 29, 65, 66, 67 Left Repeater Lamp . . . . . . . . . . . . . . . . . . 8W-10-51 Left Side Impact Airbag Control Module . . . 8W-10-62 Left Sliding Door Control Module . . . . . . . . 8W-10-52 Left Stop/Turn Signal Relay . . . . . . . . . . . . 8W-10-67 Left Turn Signal Lamp . . . . . . . . . . . . . . . . 8W-10-56 License Lamp . . . . . . . . . . . . . . . . . 8W-10-28, 29, 65 Lift Pump Motor . . . . . . . . . . . . . . . . . . 8W-10-23, 43 Lift Pump Relay . . . . . . . . . . . . . . . . . . 8W-10-23, 43 Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-10-36 Mass Air Flow Sensor . . . . . . . . . . . . . . . . . 8W-10-44 Memory Seat/Mirror Module . . . . . . . . . . . . 8W-10-49 Message Center . . . . . . . . . . . . . . . . . . . . . 8W-10-51 Name Brand Speaker Relay . . . . . . . 8W-10-20, 39, 59 Overhead Console . . . . . . . . . . . . . . . . . . . . 8W-10-40 Oxygen Sensor 1/1 Upstream . . . . . . . . . . . 8W-10-42 Oxygen Sensor 1/2 Downstream . . . . . . . . . 8W-10-42 Park Lamp Relay . . . . . . . . . . . . 8W-10-15, 28, 29, 59 Park/Neutral Position Switch . . . . . . . . . . . 8W-10-65 Passenger Door Lock Switch . . . . . . . . . 8W-10-31, 33 Passenger Folding Mirror Relay . 8W-10-22, 24, 45, 47 Passenger Heated Seat Module . . . . . . . . . . 8W-10-50 Passenger Power Seat Switch . . . . . . . . . . . 8W-10-50 Passenger Power Window Switch . . . . . . . . 8W-10-31 Power Liftgate Module . . . . . . . . . . . . . 8W-10-26, 52 Power Mirror Switch . . . . . . . . . 8W-10-22, 24, 46, 47 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36 RS Component Page Power Seat Circuit Breaker . . . . . . . . . . 8W-10-25, 49 Power Window Circuit Breaker . . . . . . . 8W-10-16, 31 Power Window Switch . . . . . . . . . . . . . . . . . 8W-10-34 Powertrain Control Module . . . . 8W-10-18, 21, 22, 37, 41, 42, 45, 46, 55 PTC 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 39 PTC 7 . . . . . . . . . . . . . . . . . . . . 8W-10-16, 17, 18, 36 Radiator Fan Relay . . . . . . . . . . . . . 8W-10-26, 51, 55 Radiator Fan Relay No. 1 . . . . . . . . . . . 8W-10-13, 44 Radiator Fan Relay No. 2 . . . . . . . . . 8W-10-26, 44, 51 Radiator Fan Relay No. 3 . . . . . . . . . . . . . . 8W-10-44 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32, 40 Radio Choke . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 39 Rear A/C-Heater Unit . . . . . . . . . . . . . . 8W-10-19, 38 Rear Blower Motor Power Module . . . . . 8W-10-19, 38 Rear Blower Motor Relay . . . . . . 8W-10-19, 20, 38, 63 Rear Power Outlet . . . . . . . . . . . . . . 8W-10-16, 31, 32 Rear Washer Pump Motor . . . . . . . . 8W-10-16, 31, 68 Rear Window Defogger Grid . . . . . . . . . 8W-10-20, 39 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . 8W-10-33 Remote Keyless Entry Module . . . . . . . . . . . 8W-10-40 Right B-Pillar Switch . . . . . . . . . . . . . . . . . 8W-10-33 Right Combination Relay . . . . . . . . . . . . . . 8W-10-67 Right Fog Lamp . . . . . . . . . . . . . . . . . . 8W-10-15, 27 Right Front Park/Turn Signal Lamp . . . . . . . . . . . . . . . . . . . 8W-10-15, 28, 56, 60 Right Headlamp . . . . . . . . . . . . . . . . . . . . . 8W-10-57 Right Headlamp Leveling Motor . . . . 8W-10-29, 60, 62 Right High Beam Lamp . . . . . . . . . . . . . . . 8W-10-58 Right Low Beam Lamp . . . . . . . . . . . . . . . . 8W-10-58 Right Park Lamp . . . . . . . . . . . . . . . . . 8W-10-29, 60 Right Power Mirror . . . . . . . . . . . . . . . . . . . 8W-10-39 Right Rear Lamp Assembly . . . . 8W-10-15, 28, 29, 66 Right Repeater Lamp . . . . . . . . . . . . . . . . . 8W-10-51 Right Side Impact Airbag Control Module . . 8W-10-62 Right Sliding Door Control Module . . . . . . . 8W-10-52 Right Stop/Turn Signal Relay . . . . . . . . . . . 8W-10-67 Right Turn Signal Lamp . . . . . . . . . . . . . . . 8W-10-56 Sentry Key Immobilizer Module . . . . . . . . . . . . . . . 8W-10-40, 46, 48, 53, 54 Solenoid/Pressure Switch Assy . . . . . . . . . . 8W-10-41 Starter Motor . . . . . . . . . . . . . . . 8W-10-13, 14, 18, 37 Starter Motor Relay . . . . . . . . . . 8W-10-18, 37, 53, 54 Thatcham Alarm Module . . . . . . 8W-10-46, 48, 54, 68 Torque Converter Clutch Solenoid . . . . . . . . 8W-10-46 Trailer Tow Connector . . . . . . . . . . . . . . 8W-10-28, 65 Transmission Control Module . . . . . . . . . . . . 8W-10-18, 21, 37, 41, 61, 62 Transmission Control Relay . . . . . . . . . . 8W-10-21, 41 Transmission Range Sensor . . . . . . . . . . . . . 8W-10-65 TXV Solenoid . . . . . . . . . . . . . . . . . . . . . . . 8W-10-38 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . 8W-10-43 Washer Fluid Level Switch . . . . . . . . . . . . . 8W-10-60 Wiper Module . . . . . . . . . . . . . . . . . 8W-10-16, 30, 59 RS 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page A/C Compressor Clutch . . . . . . . . . . . . . . . . . . . 8W-15-7, 8 A/C- Heater Control . . . . . . . . . . . . . . . . . . . . 8W-15-9, 11 Adjustable Pedals Module . . . . . . . . . . . . . . . . . . 8W-15-17 Airbag Control Module . . . . . . . . . . . . . . . . . . . . 8W-15-12 Auto Temp Control . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Automatic Day/Night Mirror . . . . . . . . . . . . . . . . . 8W-15-21 Autostick Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . . . 8W-15-3, 7 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 Body Control Module . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Brake Fluid Level Switch . . . . . . . . . . . . . . . . . . . 8W-15-17 Brake Lamp Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15-17 Cabin Heater Assist . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8 Center Dome Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-21 Center High Mounted Stop Lamp . . . . . . . . . . . . . . 8W-15-26 Clutch Pedal Upstop Switch . . . . . . . . . . . . . . . . . 8W-15-18 Controller Antilock Brake . . . . . . . . . . . . . . . . . . 8W-15-2, 3 Crank Case Ventilation Heater . . . . . . . . . . . . . . . . 8W-15-8 Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . 8W-15-3 Data Link Connector . . . . . . . . . . . . . . . . . . 8W-15-2, 3, 17 Dosing Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8 Driver Door Courtesy Lamp . . . . . . . . . . . . . . . 8W-15-15, 20 Driver Door Lock Switch . . . . . . . . . . . . . . . . . 8W-15-15, 20 Driver Heated Seat Cushion . . . . . . . . . . . . . . . . . 8W-15-11 Driver Heated Seat Module . . . . . . . . . . . . . . . . . 8W-15-11 Driver Power Seat Switch . . . . . . . . . . . . . . . . . . 8W-15-11 Driver Power Window Switch . . . . . . . . . . . . . . 8W-15-15, 20 Engine Control Module . . . . . . . . . . . . . . . . . . . . . 8W-15-3 Floor Console Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-25 Floor Console Power Outlet . . . . . . . . . . . . . . . . . 8W-15-25 Front Blower Module . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Front Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Front Control Module . . . . . . . . . . . . . . . . . . 8W-15-7, 8, 18 Front Reading Lamps/Switch . . . . . . . . . . . . . . . . 8W-15-21 Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25 Fuel Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 Fuel Pump Module . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5, 6 G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 8 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11 G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14, 16, 17, 18 G301 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19, 20, 21, 22 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23, 24, 25 G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25, 26 Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Halo Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Headlamp Washer Pump Motor . . . . . . . . . . . . . . . . 8W-15-6 High Note Horn . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6 Hood Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Instrument Panel Switch Bank . . . . . . . . . . . . . . . 8W-15-10 Integrated Power Module . . . . . . . . . . . . 8W-15-2, 3, 7, 8, 18 Left B-Pillar Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15-17 Left Cinch/Release Motor . . . . . . . . . . . . . . . . . . . 8W-15-14 Left Combination Relay . . . . . . . . . . . . . . . . . . . . 8W-15-24 Left Cylinder Lock Switch . . . . . . . . . . . . . . . . 8W-15-15, 16 Left Door Speaker . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6 Left Front Door Ajar Switch . . . . . . . . . . . . . . . . . 8W-15-16 Left Front Door Lock Motor/Ajar Switch . . . . . . . 8W-15-15, 16 Left Front Park/Turn Signal Lamp . . . . . . . . . . . . . . 8W-15-5 Left Full Open Switch . . . . . . . . . . . . . . . . . . . . . 8W-15-14 Left Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Left Headlamp Leveling Motor . . . . . . . . . . . . . . . . 8W-15-6 Left High Beam Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-18 Left Liftgate Flood Lamp . . . . . . . . . . . . . . . . . . . 8W-15-26 Left Low Beam Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Left Mid Reading Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-21 Left Park Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Left Power Mirror . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Left Rear Lamp Assembly . . . . . . . . . . . . . . . . . . 8W-15-24 Left Rear Reading Lamp . . . . . . . . . . . . . . . . . . . 8W-15-21 Left Side Impact Airbag Control Module . . . . . . . . . 8W-15-12 Left Sliding Door Control Module . . . . . . . . . . . . . . 8W-15-14 Left Sliding Door Latch Sensing Switch . . . . . . . . . . 8W-15-14 Left Sliding Door Lock Motor . . . . . . . . . . . . . . . . 8W-15-14 Component Page Left Sliding Door Lock Motor/Ajar Switch . . . . . . . . . 8W-15-14 Left Sliding Door Motor . . . . . . . . . . . . . . . . . . . . 8W-15-14 Left Stop/Turn Signal Relay . . . . . . . . . . . . . . . . . 8W-15-24 Left Turn Signal Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-18 Left Visor/Vanity Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-21 License Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23, 26 Lift Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25 Liftgate Ajar Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15-26 Liftgate Cinch/Release Motor . . . . . . . . . . . . . . . . 8W-15-23 Liftgate Cylinder Lock Switch . . . . . . . . . . . . . . . . 8W-15-26 Liftgate Right Pinch Sensor . . . . . . . . . . . . . . . . . 8W-15-23 Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6 Memory Seat/Mirror Module . . . . . . . . . . . . . . . . . 8W-15-11 Overhead Console . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21 Oxygen Sensor 1/2 Downstream . . . . . . . . . . . . . . . 8W-15-7 Park/Neutral Position Switch . . . . . . . . . . . . . . . . . 8W-15-7 Passenger Door Courtesy Lamp . . . . . . . . . . . . 8W-15-16, 20 Passenger Door Lock Switch . . . . . . . . . . . . . . 8W-15-16, 20 Passenger Heated Seat Module . . . . . . . . . . . . . . . 8W-15-22 Passenger Power Seat Switch . . . . . . . . . . . . . . . . 8W-15-22 Passenger Power Window Switch . . . . . . . . . . . . 8W-15-16, 20 Power Folding Mirror Switch . . . . . . . . . . . . . . . . 8W-15-11 Power Liftgate Module . . . . . . . . . . . . . . . . . . . . 8W-15-23 Power Liftgate Motor . . . . . . . . . . . . . . . . . . . . . 8W-15-23 Power Mirror Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Power Window Switch . . . . . . . . . . . . . . . . . . . . . 8W-15-15 Powertrain Control Module . . . . . . . . . . . . . . . . . . 8W-15-2 Radiator Fan No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Radiator Fan No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Radiator Fan Relay No. 3 . . . . . . . . . . . . . . . . . . . 8W-15-4 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 Rear Auto Temp Control Switch . . . . . . . . . . . . . . . 8W-15-17 Rear Blower Front Control Switch . . . . . . . . . . . . . 8W-15-11 Rear Blower Motor Power Module . . . . . . . . . . . 8W-15-11, 25 Rear Blower Rear Control Switch . . . . . . . . . . . . . . 8W-15-17 Rear Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21 Rear Power Outlet . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25 Rear Window Defogger Grid . . . . . . . . . . . . . . . . . 8W-15-26 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-15-26 Remote Keyless Entry Module . . . . . . . . . . . . . . . . 8W-15-10 Right B-Pillar Switch . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Right Cinch/Release Motor . . . . . . . . . . . . . . . . . . 8W-15-19 Right Combination Relay . . . . . . . . . . . . . . . . . . . 8W-15-24 Right Cylinder Lock Switch . . . . . . . . . . . . . . . . . 8W-15-20 Right Door Speaker . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6 Right Front Door Ajar Switch . . . . . . . . . . . . . . . . 8W-15-20 Right Front Door Lock Motor/Ajar Switch . . . . . . . . . 8W-15-20 Right Front Park/Turn Signal Lamp . . . . . . . . . . . . . 8W-15-5 Right Full Open Switch . . . . . . . . . . . . . . . . . . . . 8W-15-19 Right Headlamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Right Headlamp Leveling Motor . . . . . . . . . . . . . . . 8W-15-6 Right High Beam Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-18 Right Liftgate Flood Lamp . . . . . . . . . . . . . . . . . . 8W-15-26 Right Low Beam Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-18 Right Mid Reading Lamp . . . . . . . . . . . . . . . . . . . 8W-15-21 Right Park Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Right Power Mirror . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Right Rear Lamp Assembly . . . . . . . . . . . . . . . . . 8W-15-25 Right Rear Reading Lamp . . . . . . . . . . . . . . . . . . 8W-15-21 Right Side Impact Airbag Control Module . . . . . . . . . 8W-15-12 Right Sliding Door Control Module . . . . . . . . . . . . . 8W-15-19 Right Sliding Door Latch Sensing Switch . . . . . . . . . 8W-15-19 Right Sliding Door Lock Motor . . . . . . . . . . . . . . . 8W-15-19 Right Sliding Door Lock Motor/Ajar Switch . . . . . . . . 8W-15-19 Right Sliding Door Motor . . . . . . . . . . . . . . . . . . . 8W-15-19 Right Stop/Turn Signal Relay . . . . . . . . . . . . . . . . 8W-15-24 Right Turn Signal Lamp . . . . . . . . . . . . . . . . . . . 8W-15-18 Right Visor/Vanity Lamp . . . . . . . . . . . . . . . . . . . 8W-15-21 Sentry Key Immobilizer Module . . . . . . . . . . . . . . . 8W-15-10 Speed Control Servo . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7 Traction Control Switch . . . . . . . . . . . . . . . . . . . . 8W-15-10 Trailer Tow Connector . . . . . . . . . . . . . . . . . . . . . 8W-15-24 Transmission Control Module . . . . . . . . . . . . . . . . . 8W-15-2 Transmission Control Relay . . . . . . . . . . . . . . . . . . 8W-15-2 Transmission Range Sensor . . . . . . . . . . . . . . . . . . 8W-15-7 Washer Fluid Level Switch . . . . . . . . . . . . . . . . . 8W-15-5, 6 Wiper Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17 RS 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page A/C- Heater Control . . . . . . . . . . . . . . . . . . 8W-18-4 Adjustable Pedals Module . . . . . . . . . . . . . . 8W-18-5 Airbag Control Module . . . . . . . . . . . . . . . . 8W-18-4 Auto Temp Control . . . . . . . . . . . . . . . . . . . 8W-18-4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 3 Body Control Module . . . . . . . . . . . . . 8W-18-2, 3, 4 Cabin Heater Assist . . . . . . . . . . . . . . . . . . 8W-18-3 CD Changer . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4 Controller Antilock Brake . . . . . . . . . . . . . . 8W-18-4 Data Link Connector . . . . . . . . . . . . . . 8W-18-2, 3, 4 Diagnostic Junction Port . . . . . . . . . 8W-18-2, 3, 4, 5 Engine Control Module . . . . . . . . . . . . . . 8W-18-3, 5 Front Control Module . . . . . . . . . . . . . 8W-18-2, 3, 4 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 3 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 3 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 3 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-18-4 Component Page Integrated Power Module . . . . . . . . . . . . 8W-18-2, 3 Integrated Power Module . . . . . . . . . . . . . . 8W-18-4 Left Side Impact Airbag Control Module . . . 8W-18-5 Left Sliding Door Control Module . . . . . . . . 8W-18-5 Memory Seat/Mirror Module . . . . . . . . . . . . 8W-18-5 Overhead Console . . . . . . . . . . . . . . . . . . . . 8W-18-4 Power Liftgate Module . . . . . . . . . . . . . . . . 8W-18-5 Powertrain Control Module . . . . . . . . . . . 8W-18-2, 5 PTC 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 3 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4 Right Side Impact Airbag Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5 Right Sliding Door Control Module . . . . . . . 8W-18-5 Sentry Key Immobilizer Module . . . . . . . . . 8W-18-5 Thatcham Alarm Module . . . . . . . . . . . 8W-18-2, 3, 5 Transmission Control Module . . . . . . . . . 8W-18-2, 4 RS 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Auto Shut Down Relay . . . . . . . . . . . . . . . . 8W-20-2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3 Battery Temperature Sensor . . . . . . . . . . . . 8W-20-3 ECM/PCM Relay . . . . . . . . . . . . . . . . . . . . . 8W-20-3 Engine Control Module . . . . . . . . . . . . . . . . 8W-20-3 Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3 Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2 Component Page Fuselink . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3 Generator . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3 Integrated Power Module . . . . . . . . . . . . 8W-20-2, 3 Powertrain Control Module . . . . . . . . . . . . . 8W-20-2 Starter Motor . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3 RS 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 Clutch Pedal Interlock Switch . . . . . . . . . 8W-21-2, 3 Clutch Pedal Interlock Switch Jumper . . . . 8W-21-2 Engine Control Module . . . . . . . . . . . . . . . . 8W-21-3 Front Control Module . . . . . . . . . . . . . . . . . 8W-21-2 Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 Fuselink . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 Component Page G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 Generator . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 Ignition Switch . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 Integrated Power Module . . . . . . . . . . . . 8W-21-2, 3 Powertrain Control Module . . . . . . . . . . . . . 8W-21-2 Starter Motor . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 Starter Motor Relay . . . . . . . . . . . . . . . . 8W-21-2, 3 RS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page A/C Compressor Clutch . . . . . . . . . . . . . . . 8W-30-18 A/C Compressor Clutch Relay . . . . . . . . 8W-30-3, 18 A/C Pressure Sensor . . . . . . . . . . . . 8W-30-9, 15, 25 Accelerator Pedal Position Sensor . . . . . . . 8W-30-32 Adjustable Pedals Module . . . . . . . . . . . . . 8W-30-17 Adjustable Pedals Switch . . . . . . . . . . . . . 8W-30-17 Auto Shut Down Relay . . . . 8W-30-2, 5, 7, 8, 12, 13 Battery . . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 18, 26 Battery Temperature Sensor . . . . . . . . . . . 8W-30-25 Body Control Module . . . . . . . . . . . . . . 8W-30-4, 19 Boost Pressure Sensor . . . . . . . . . . . . . . . . 8W-30-25 Brake Lamp Switch . . . . . . . . . . . . . 8W-30-6, 21, 31 Cabin Heater Assist . . . . . . . . . . . . . . . . . 8W-30-22 Camshaft Position Sensor . . . . . . . . 8W-30-7, 13, 24 Clockspring . . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 23 Clutch Pedal Upstop Switch . . . . . . . . . . . 8W-30-30 Crank Case Ventilation Heater . . . . . . . . . 8W-30-19 Crankshaft Position Sensor . . . . . . . 8W-30-7, 13, 24 Data Link Connector . . . . . . . . . . . . . . . 8W-30-4, 22 Diagnostic Junction Port . . . . . . . . . 8W-30-4, 23, 17 Dosing Pump . . . . . . . . . . . . . . . . . . . . . . . 8W-30-22 ECM/PCM Relay . . . . . . . . 8W-30-18, 20, 24, 26, 28 EGR Solenoid . . . . . . . . . . . . . . . . . . . . 8W-30-5, 28 Engine Control Module . . . 8W-30-18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32 Engine Coolant Temp Sensor . . . . . . 8W-30-9, 15, 25 Engine Oil Pressure Sensor . . . . . . . . . . . 8W-30-21 Engine Oil Pressure Switch . . . . . . . . . . . . 8W-30-6 Engine Oil Temperature Sensor . . . . . . . . 8W-30-24 Evap/Purge Solenoid . . . . . . . . . . . . . . . . . . 8W-30-3 Front Control Module . . . . . . 8W-30-3, 4, 17, 22, 30 Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-29 Fuel Heater Relay . . . . . . . . . . . . . . . . 8W-30-19, 29 Fuel Injector No. 1 . . . . . . . . . . . . . 8W-30-8, 12, 27 Fuel Injector No. 2 . . . . . . . . . . . . . 8W-30-8, 12, 27 Fuel Injector No. 3 . . . . . . . . . . . . . 8W-30-8, 12, 27 Fuel Injector No. 4 . . . . . . . . . . . . . 8W-30-8, 12, 27 Fuel Injector No. 5 . . . . . . . . . . . . . . . . . . 8W-30-12 Fuel Injector No. 6 . . . . . . . . . . . . . . . . . . 8W-30-12 Fuel Pressure Sensor . . . . . . . . . . . . . . . . 8W-30-31 Fuel Pressure Solenoid . . . . . . . . . . . . . . . 8W-30-20 Fuel Pump Module . . . . . . . . . . . . . . . . 8W-30-4, 19 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . 8W-30-4 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17 Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-22, 29 Fuse 16 . . 8W-30-2, 5, 7, 8, 12, 13, 18, 20, 24, 26, 28 Fuse 17 . . . . . . . . . . . . . . . . . . . . 8W-30-2, 4, 19, 29 Component Page Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18, 17 Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-31 Fuselink . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-26 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 18 G103 . . . . . . . . . . . . . . . . . . . 8W-30-5, 6, 18, 19, 22 G300 . . . . . . . . . . . . . . . . . . . . . 8W-30-6, 17, 21, 30 G302 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 19, 29 Generator . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 19 Glow Plug No. 1 . . . . . . . . . . . . . . . . . . . . 8W-30-26 Glow Plug No. 2 . . . . . . . . . . . . . . . . . . . . 8W-30-26 Glow Plug No. 3 . . . . . . . . . . . . . . . . . . . . 8W-30-26 Glow Plug No. 4 . . . . . . . . . . . . . . . . . . . . 8W-30-26 Glow Plug Relay . . . . . . . . . . . . . . . . . . . . 8W-30-26 Idle Air Control Motor . . . . . . . . . . . . . 8W-30-11, 14 Ignition Coil . . . . . . . . . . . . . . . . . . . . . 8W-30-7, 13 Ignition Switch . . . . . . . . . . . . . . . . . . . . . 8W-30-16 Inlet Air Temperature Sensor . . . . . . . 8W-30-10, 14 Integrated Power Module . . . . . . . . . . 8W-30-2, 3, 4, 5, 7, 8, 12, 13, 18, 19, 20, 22, 24, 26, 28, 29, 30, 31 Knock Sensor . . . . . . . . . . . . . . . . . . . . 8W-30-9, 15 Leak Detection Pump . . . . . . . . . . . . . . . . 8W-30-16 Left Speed Control Switch . . . . . . . . . . . 8W-30-3, 23 Lift Pump Motor . . . . . . . . . . . . . . . . . . . . 8W-30-29 Lift Pump Relay . . . . . . . . . . . . . . . . . . . . 8W-30-29 Manifold Absolute Pressure Sensor . . . . 8W-30-9, 15 Mass Air Flow Sensor . . . . . . . . . . . . . . . . 8W-30-20 Oxygen Sensor 1/1 Upstream . . . . . . . . . . . 8W-30-5 Oxygen Sensor 1/2 Downstream . . . . . . . . . 8W-30-5 Park/Neutral Position Switch . . . . . . . . . . 8W-30-11 Power Mirror Switch . . . . . . . . . . . . . . . . . 8W-30-17 Powertrain Control Module . 8W-30-2, 3, 4, 5, 6, 10, 11, 7, 8, 9, 12, 13, 14, 15, 16 Radiator Fan Relay . . . . . . . . . . . . . . . . . . . 8W-30-3 Radiator Fan Relay No. 1 . . . . . . . . . . . . . 8W-30-31 Radiator Fan Relay No. 2 . . . . . . . . . . . . . 8W-30-31 Radiator Fan Relay No. 3 . . . . . . . . . . . . . 8W-30-31 Right Speed Control Switch . . . . . . . . . 8W-30-3, 23 Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-30-6 Starter Motor Relay . . . . . . . . . . . . . . . 8W-30-4, 19 Throttle Position Sensor . . . . . . . . . . . 8W-30-10, 14 Torque Converter Clutch Solenoid . . . . . . . 8W-30-16 Transmission Control Module . . 8W-30-7, 10, 11, 14 Transmission Range Sensor . . . . . . . . . 8W-30-11, 14 Vehicle Speed Sensor . . . . . . . . . . . . 8W-30-7, 11, 28 Water In Fuel Sensor . . . . . . . . . . . . . . . . 8W-30-30 RS 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Autostick Switch . . . . . . . . . . . . . . . . . . . . . 8W-31-5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2 Brake Transmission Shift Interlock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4 Crankshaft Position Sensor . . . . . . . . . . . . 8W-31-3 Data Link Connector . . . . . . . . . . . . . . . . . 8W-31-8 Front Control Module . . . . . . . . . . . 8W-31-4, 5, 8, 9 Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 6, 7 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2 G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5, 9 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . 8W-31-9 Component Page Input Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31-5 Integrated Power Module . . 8W-31-2, 4, 5, 6, 7, 8, 9 Output Speed Sensor . . . . . . . . . . . . . . . . . 8W-31-5 Park/Neutral Position Switch . . . . . . . . . . . 8W-31-9 Powertrain Control Module . . . . . . . 8W-31-3, 4, 8, 9 Solenoid/Pressure Switch Assy . . . . . . . . 8W-31-6, 7 Throttle Position Sensor . . . . . . . . . . . . . . . 8W-31-3 Torque Converter Clutch Solenoid . . . . . . . 8W-31-9 Transmission Control Module . . . . . . . . . . . . . . 8W-31-2, 3, 4, 5, 6, 7, 8 Transmission Control Relay . . . . . . . . 8W-31-2, 6, 7 Transmission Range Sensor . . . . . . . . . . 8W-31-4, 5 RS 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-33-3 Clockspring . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2, 4 Clutch Pedal Upstop Switch . . . . . . . . . . . . 8W-33-4 Engine Control Module . . . . . . . . . . . . . . . . 8W-33-4 G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-4 Component Page Left Speed Control Switch . . . . . . . . . . . 8W-33-2, 4 Powertrain Control Module . . . . . . . . . . . 8W-33-2, 3 Right Speed Control Switch . . . . . . . . . . 8W-33-2, 4 Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-33-3 Transmission Control Module . . . . . . . . . . . 8W-33-2 Vehicle Speed Sensor . . . . . . . . . . . . . . . 8W-33-2, 4 RS 8W-35 ANTILOCK BRAKES 8W - 35 - 1 8W-35 ANTILOCK BRAKES Component Body Control Module . . . Brake Lamp Switch . . . . Controller Antilock Brake Diagnostic Junction Port . Engine Control Module . . Front Control Module . . . Fuse 9 . . . . . . . . . . . . . . . Fuse 21 . . . . . . . . . . . . . . Fuse 26 . . . . . . . . . . . . . . G100 . . . . . . . . . . . . . . . . Page . . . . . . . . . . . . . . 8W-35-2 . . . . . . . . . . . . . . 8W-35-3 . . . . . . . . . . 8W-35-2, 3, 4 . . . . . . . . . . . . . . 8W-35-3 . . . . . . . . . . . . . . 8W-35-3 . . . . . . . . . . . . . . 8W-35-3 . . . . . . . . . . . . . . 8W-35-2 . . . . . . . . . . . . . . 8W-35-2 . . . . . . . . . . . . . . 8W-35-3 . . . . . . . . . . . . . . 8W-35-2 Component Page G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3 Integrated Power Module . . . . . . . . . . . . 8W-35-2, 3 Left Front Wheel Speed Sensor . . . . . . . . . 8W-35-4 Left Rear Wheel Speed Sensor . . . . . . . . . . 8W-35-4 Powertrain Control Module . . . . . . . . . . . . . 8W-35-3 Right Front Wheel Speed Sensor . . . . . . . . 8W-35-4 Right Rear Wheel Speed Sensor . . . . . . . . . 8W-35-4 Traction Control Switch . . . . . . . . . . . . . . . 8W-35-2 RS 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Body Control Module . . . . . . . . . 8W-39-2, 4, 7, 8, 9, 10, 11, 12, 13, 14, 15 Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6 Data Link Connector . . . . . . . . . . . . . . . . . 8W-39-4 Diagnostic Junction Port . . . . . . . . . . . . . . . 8W-39-4 Driver Door Lock Switch . . . . . . . . . . . 8W-39-12, 13 Engine Control Module . . . . . . . . . . . . . . . . 8W-39-3 Front Control Module . . . . . . . . . . . . . . . 8W-39-4, 6 Front Intrusion Sensor . . . . . . . . . . . . . . . . 8W-39-5 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2 Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2 G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3 G300 . . . . . . . . . . . . 8W-39-7, 8, 9, 10, 11, 12, 13, 14 G301 . . . . . . . . . . . . . . . 8W-39-7, 8, 9, 10, 11, 12, 13 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-15 G400 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-14, 15 High Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-39-6 Hood Ajar Switch . . . . . . . . . . . . . . . . . . . 8W-39-14 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6 Ignition Switch . . . . . . . . . . . . . . . . . . . . 8W-39-3, 4 Integrated Power Module . . . . . . . . . . 8W-39-2, 4, 6 Left Cylinder Lock Switch . . . . . . . . . . 8W-39-12, 13 Left Front Door Ajar Switch . . . . . . . . . . . . 8W-39-7 Left Front Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8 Left Sliding Door Control Module . . . . . 8W-39-9, 10 Component Page Left Sliding Door Latch Sensing Switch . . . 8W-39-9 Left Sliding Door Lock Motor . . . . . . . . . . 8W-39-10 Left Sliding Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-11 Liftgate Ajar Switch . . . . . . . . . . . . . . . . . 8W-39-15 Liftgate Cinch/Release Motor . . . . . . . . . . 8W-39-15 Liftgate Cylinder Lock Switch . . . . . . . . . . 8W-39-14 Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-39-6 Message Center . . . . . . . . . . . . . . . . . . . . . 8W-39-2 Passenger Door Lock Switch . . . . . . . . 8W-39-12, 13 Power Liftgate Module . . . . . . . . . . . . . . . 8W-39-15 Powertrain Control Module . . . . . . . . . . . . . 8W-39-3 Rear Intrusion Sensor . . . . . . . . . . . . . . . . . 8W-39-5 Remote Keyless Entry Module . . . . . . . . . . 8W-39-2 Right Cylinder Lock Switch . . . . . . . . . 8W-39-12, 13 Right Front Door Ajar Switch . . . . . . . . . . . 8W-39-7 Right Front Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8 Right Sliding Door Control Module . . . . 8W-39-9, 10 Right Sliding Door Latch Sensing Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-9 Right Sliding Door Lock Motor . . . . . . . . . 8W-39-10 Right Sliding Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-11 Sentry Key Immobilizer Module . . . . . . . 8W-39-2, 3 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4 Thatcham Alarm Indicator . . . . . . . . . . . . . 8W-39-5 Thatcham Alarm Module . . . . . . . . . . . . 8W-39-4, 5 RS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Airbag Control Module . . . . . . . . . . . . . . . . 8W-40-2 Body Control Module . . . . . . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10, 11 Brake Fluid Level Switch . . . . . . . . . . . . . . 8W-40-9 Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-9 Diagnostic Junction Port . . . . . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9, 12 Engine Control Module . . . . . . . . . . . 8W-40-8, 9, 12 Engine Coolant Temp Sensor . . . . . . . . . 8W-40-7, 8 Engine Oil Pressure Sensor . . . . . . . . . . . 8W-40-12 Engine Oil Pressure Switch . . . . . . . . . . . 8W-40-12 Front Control Module . . . . . . . . . . . . . . . . . 8W-40-9 Fuel Pump Module . . . . . . . . . . . . . . . . . . . 8W-40-2 Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2 G200 . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 10, 11, 12 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-9 Instrument Cluster . . . . . . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 Integrated Power Module . . . . . . . . . . . . 8W-40-2, 9 Left Front Door Ajar Switch . . . . . . . . . . . . 8W-40-3 Left Front Door Lock Motor/Ajar Switch . . . 8W-40-3 Left Sliding Door Control Module . . . . . . . . 8W-40-4 Left Sliding Door Latch Sensing Switch . . . 8W-40-4 Component Page Left Sliding Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4 Left Speed Control Switch . . . . . . . . . . . . . 8W-40-9 Liftgate Ajar Switch . . . . . . . . . . . . . . . . . . 8W-40-3 Liftgate Cinch/Release Motor . . . . . . . . . . . 8W-40-3 Message Center . . . . . . . . . . . . . . . . . . . 8W-40-6, 12 Multi- Function Switch . . . . . . . . . . . . . . . . 8W-40-6 Parking Brake Switch . . . . . . . . . . . . . 8W-40-10, 11 Powertrain Control Module . . . . . . . . 8W-40-7, 9, 12 Right Front Door Ajar Switch . . . . . . . . . . . 8W-40-3 Right Front Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3 Right Sliding Door Control Module . . . . . . . 8W-40-5 Right Sliding Door Latch Sensing Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5 Right Sliding Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5 Right Speed Control Switch . . . . . . . . . . . . 8W-40-9 Traction Control Switch . . . . . . . . . . . . . 8W-40-7, 8 Transmission Control Module . . . . . . . . . . . 8W-40-7 Vehicle Speed Sensor . . . . . . . . . . . . . . . 8W-40-7, 8 Washer Fluid Level Switch . . . . . . . . . . . . . 8W-40-9 RS 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Accessory Relay . . . . . . . . . . . . . . . . . . . 8W-41-3, 4 Body Control Module . . . . . . . . . . . . . . . . . 8W-41-3 Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Floor Console Power Outlet . . . . . . . . . . . . 8W-41-4 Front Cigar Lighter . . . . . . . . . . . . . . . . . . 8W-41-3 Front Control Module . . . . . . . . . . . . . 8W-41-2, 3, 4 Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3, 4 Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3, 4 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3, 4 Component Page G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3, 4 High Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Integrated Power Module . . . . . . . . . . 8W-41-2, 3, 4 Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4 PTC 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3 Rear Power Outlet . . . . . . . . . . . . . . . . . . . 8W-41-3 RS 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page A/C Compressor Clutch . . . . . . . . . . . . 8W-42-14, 16 A/C Compressor Clutch Relay . . . . . . . 8W-42-14, 16 A/C Pressure Sensor . . . . . . . . . . . . . . 8W-42-14, 16 A/C- Heater Control . . . . . . . . . . 8W-42-2, 3, 4, 5, 7 ATC Remote Sensor . . . . . . . . . . . . . . . . . 8W-42-11 Auto Temp Control . . . . . . 8W-42-8, 9, 10, 11, 12, 13 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-17 Blower Motor Resistor . . . . . . . . . . . . . . . . 8W-42-2 Body Control Module . . . . . . . . . . . 8W-42-4, 7, 9, 13 Diagnostic Junction Port . . . . . . . . . . . . . 8W-42-4, 9 Driver Blend Door Actuator . . . . . . . . . 8W-42-5, 10 ECM/PCM Relay . . . . . . . . . . . . . . . . . . . . 8W-42-17 Electric Wiper De-Icer . . . . . . . . . . . . . . . 8W-42-3, 8 Engine Control Module . . . . . . . . . . . . 8W-42-16, 17 Evaporator Temperature Sensor . . . . . . 8W-42-5, 10 Front Blower Module . . . . . . . . . . . . . . . . 8W-42-11 Front Blower Motor . . . . . . . . . . . . . . . . 8W-42-2, 11 Front Blower Motor Relay . . . . . . . . . . . 8W-42-2, 11 Front Control Module . . . . . . . . . 8W-42-2, 6, 11, 12 Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 11 Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 12 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8 Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-17 Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-14, 16 Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-15, 18 Fuselink . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-17 G102 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-15, 18 Component Page G103 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-14, 16 G200 . . . . . . . . . . . . . . 8W-42-2, 3, 4, 6, 8, 9, 11, 12 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7, 13 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-12 Integrated Power Module . . 8W-42-2, 6, 8, 11, 12, 14, 15, 16, 17, 18 Mode Door Actuator . . . . . . . . . . . . . . . 8W-42-5, 10 Passenger Blend Door Actuator . . . . . . . 8W-42-5, 10 Powertrain Control Module . . . . . . . . . 8W-42-14, 15 Radiator Fan No. 1 . . . . . . . . . . . . 8W-42-15, 17, 18 Radiator Fan No. 2 . . . . . . . . . . . . . . . 8W-42-15, 18 Radiator Fan Relay . . . . . . . . . . . . . . . . . . 8W-42-15 Radiator Fan Relay No. 1 . . . . . . . . . . 8W-42-17, 18 Radiator Fan Relay No. 2 . . . . . . . . . . . . . 8W-42-18 Radiator Fan Relay No. 3 . . . . . . . . . . . . . 8W-42-18 Rear A/C-Heater Unit . . . . . . . . . . . . . . . 8W-42-6, 7 Rear Auto Temp Control Switch . . . . . . . . 8W-42-13 Rear Blower Front Control Switch . . . . . . . 8W-42-6 Rear Blower Motor . . . . . . . . . . . . . . . . . . 8W-42-12 Rear Blower Motor Power Module . . . . . . 8W-42-12 Rear Blower Motor Relay . . . . . . . . . . . 8W-42-6, 12 Rear Blower Rear Control Switch . . . . . . 8W-42-6, 7 Rear Mode Motor . . . . . . . . . . . . . . . . . . . 8W-42-12 Rear Temperature Motor . . . . . . . . . . . . . . 8W-42-12 Recirculation Door Actuator . . . . . . . . . 8W-42-5, 10 TXV Solenoid . . . . . . . . . . . . . . . . . . . . . . 8W-42-12 2002 RS Service Manual Publication No. 81-370-02062 TSB 26-12-01 December, 2001 2002 RS Service Manual Publication No. 81-370-02062 TSB 26-12-01 December, 2001 RS 8W-43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Airbag Control Module . . . . . . . . . . 8W-43-2, 3, 4, 5 Body Control Module . . . . . . . . . . . . . . . 8W-43-6, 7 Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-4 Diagnostic Junction Port . . . . . . . . . . . 8W-43-2, 6, 7 Driver Airbag . . . . . . . . . . . . . . . . . . . . . . . 8W-43-4 Driver Seat Belt Switch . . . . . . . . . . . . . . . 8W-43-3 Driver Seat Belt Tensioner . . . . . . . . . . . . . 8W-43-3 Front Control Module . . . . . . . . . . . . . 8W-43-2, 6, 7 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2 G201 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2, 6, 7 Component Page Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-43-2 Integrated Power Module . . . . . . . . . . 8W-43-2, 6, 7 Left Seat Airbag . . . . . . . . . . . . . . . . . . . . . 8W-43-6 Left Side Impact Airbag Control Module . . . 8W-43-6 Passenger Airbag . . . . . . . . . . . . . . . . . . . . 8W-43-5 Passenger Seat Belt Switch . . . . . . . . . . . . 8W-43-5 Passenger Seat Belt Tensioner . . . . . . . . . . 8W-43-5 Right Seat Airbag . . . . . . . . . . . . . . . . . . . . 8W-43-7 Right Side Impact Airbag Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-7 RS 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page A/C- Heater Control . . . . . . . . . . . . . . . . . . 8W-44-8 Accessory Relay . . . . . . . . . . . . . . . . . . . . . 8W-44-4 Auto Temp Control . . . . . . . . . . . . . . . . . . . 8W-44-8 Body Control Module . . . . . . 8W-44-2, 3, 4, 5, 6, 7, 8 Center Dome Lamp . . . . . . . . . . . . . . . . . . . 8W-44-5 Driver Door Courtesy Lamp . . . . . . . . . . . . 8W-44-2 Floor Console Lamp . . . . . . . . . . . . . . . . . . 8W-44-4 Front Cigar Lighter . . . . . . . . . . . . . . . . . . 8W-44-7 Front Control Module . . . . . . . . . . . . . . . . . 8W-44-4 Front Reading Lamps/Switch . . . . . . . . . 8W-44-4, 5 Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4 G200 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 5, 7, 8 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 8 G301 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 5, 6 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4 G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . 8W-44-5 Halo Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Headlamp Switch . . . . . . . . . . . . 8W-44-3, 5, 6, 7, 8 Component Instrument Cluster . . . . . . . . . . . Instrument Panel Switch Bank . . Integrated Power Module . . . . . . Left Liftgate Flood Lamp . . . . . . Left Mid Reading Lamp . . . . . . . Left Rear Reading Lamp . . . . . . . Left Visor/Vanity Lamp . . . . . . . . Overhead Console . . . . . . . . . . . . Passenger Door Courtesy Lamp . Power Mirror Switch . . . . . . . . . . Radio . . . . . . . . . . . . . . . . . . . . . Rear Auto Temp Control Switch . Rear Blower Rear Control Switch Rear Dome Lamp . . . . . . . . . . . . Right Liftgate Flood Lamp . . . . . Right Mid Reading Lamp . . . . . . Right Rear Reading Lamp . . . . . Right Visor/Vanity Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8W-44-7 8W-44-7 8W-44-4 8W-44-2 8W-44-3 8W-44-3 8W-44-6 8W-44-5 8W-44-2 8W-44-8 8W-44-7 8W-44-8 8W-44-8 8W-44-5 8W-44-2 8W-44-3 8W-44-3 8W-44-6 RS 8W-45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE Component Page A/C- Heater Control . . . . . . . . . . . . . . 8W-45-16, 19 Auto Temp Control . . . . . . . . . . . . . . . 8W-45-16, 19 Automatic Day/Night Mirror . . . . . . . . . . . 8W-45-11 Body Control Module . . . 8W-45-2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20 Center Dome Lamp . . . . . . . . . . . . . . . . 8W-45-9, 13 Clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-17 Controller Antilock Brake . . . . . . . . . . . . . 8W-45-13 Diagnostic Junction Port . . . . . . . . . . . . . . 8W-45-12 Driver Door Courtesy Lamp . . . . . . . . . . . 8W-45-15 Driver Door Lock Switch . . . . . . . . . . . 8W-45-12, 15 Driver Heated Seat Module . . . . . . . . . . . . 8W-45-11 Floor Console Lamp . . . . . . . . . . . . . . . . . 8W-45-13 Front Cigar Lighter . . . . . . . . . . . . . . . . . 8W-45-17 Front Control Module . . . . . . . . . . . . . . . . . 8W-45-3 Front Reading Lamps/Switch . . . . . . . . 8W-45-8, 13 Fuel Pump Module . . . . . . . . . . . . . . . . . . 8W-45-15 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3 Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6, 8 Glove Box Lamp . . . . . . . . . . . . . . . . . . . . 8W-45-19 Halo Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-19 Headlamp Switch . . . . . . . . . . . . . . 8W-45-11, 16, 20 Hood Ajar Switch . . . . . . . . . . . . . . . . . . . 8W-45-12 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . 8W-45-3 Instrument Cluster . . . . . . . . . . . . 8W-45-16, 18, 19 Instrument Panel Switch Bank . . . . . . . . . . . . . . . . . . 8W-45-10, 11, 17, 19 Integrated Power Module . . . . . 8W-45-2, 3, 5, 6, 13 Left B-Pillar Switch . . . . . . . . . . . . . . . . . . 8W-45-9 Left Cylinder Lock Switch . . . . . . . . . . . . . 8W-45-10 Left Front Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4, 7 Left Liftgate Flood Lamp . . . . . . . . . . . . . 8W-45-12 Left Mid Reading Lamp . . . . . . . . . . . . 8W-45-9, 14 Left Power Mirror . . . . . . . . . . . . . . . . . . . 8W-45-20 Left Rear Lamp Assembly . . . . . . . . . . . . 8W-45-5, 6 Left Rear Reading Lamp . . . . . . . . . . . . 8W-45-9, 14 Left Remote Radio Switch . . . . . . . . . . . . . 8W-45-17 Left Repeater Lamp . . . . . . . . . . . . . . . . . 8W-45-20 Left Sliding Door Control Module . . . . . 8W-45-8, 10 Left Sliding Door Lock Motor . . . . . . . . . . . 8W-45-7 Left Sliding Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7, 8 Component Page Left Stop/Turn Signal Relay . . . . . . . . . . . . 8W-45-5 Left Visor/Vanity Lamp . . . . . . . . . . . . . . . 8W-45-13 License Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-45-8 Liftgate Ajar Switch . . . . . . . . . . . . . . . . . 8W-45-12 Liftgate Cinch/Release Motor . . . . . . . . . . 8W-45-12 Liftgate Cylinder Lock Switch . . . . . . . . . . 8W-45-9 Memory Set Switch . . . . . . . . . . . . . . . . . . . 8W-45-4 Message Center . . . . . . . . . . . . . . . . . . . . . 8W-45-18 Multi- Function Switch . . . . . . . . . . . . . . . 8W-45-16 Name Brand Speaker Relay . . . . . . . . . . . . 8W-45-3 Overhead Console . . . . . . . . . . . . . . . . . 8W-45-4, 11 Passenger Door Courtesy Lamp . . . . . . . . 8W-45-15 Passenger Door Lock Switch . . . . . . . . 8W-45-12, 15 Passenger Folding Mirror Relay . . . . . . . . 8W-45-20 Passenger Heated Seat Module . . . . . . . . . 8W-45-11 Power Folding Mirror Switch . . . . . . . . . . 8W-45-20 Power Liftgate Module . . . . . . . . . . . . . . . . 8W-45-8 Power Mirror Switch . . . . . . . . . . . . . . . . . 8W-45-16 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-17 Rear Auto Temp Control Switch . . . . . 8W-45-10, 19 Rear Blower Rear Control Switch . . . . . . . 8W-45-10 Rear Dome Lamp . . . . . . . . . . . . . . . . . . . . 8W-45-9 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . 8W-45-8 Remote Keyless Entry Module . . . . . . . 8W-45-4, 16 Right B-Pillar Switch . . . . . . . . . . . . . . . . . 8W-45-9 Right Combination Relay . . . . . . . . . . . . . . 8W-45-5 Right Cylinder Lock Switch . . . . . . . . . . . 8W-45-10 Right Front Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7, 9 Right Liftgate Flood Lamp . . . . . . . . . . . . 8W-45-12 Right Mid Reading Lamp . . . . . . . . . . . 8W-45-9, 14 Right Power Mirror . . . . . . . . . . . . . . . . . . 8W-45-20 Right Rear Lamp Assembly . . . . . . . . . . . 8W-45-5, 6 Right Rear Reading Lamp . . . . . . . . . . . 8W-45-9, 14 Right Remote Radio Switch . . . . . . . . . . . 8W-45-17 Right Repeater Lamp . . . . . . . . . . . . . . . . 8W-45-20 Right Sliding Door Control Module . . . . 8W-45-8, 10 Right Sliding Door Lock Motor . . . . . . . . . . 8W-45-7 Right Sliding Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7, 8 Right Visor/Vanity Lamp . . . . . . . . . . . . . . 8W-45-13 Thatcham Alarm Module . . . . . . . . . . . . . 8W-45-10 Traction Control Switch . . . . . . . . . . . . . . 8W-45-17 RS 8W-46 MESSAGE CENTER 8W - 46 - 1 8W-46 MESSAGE CENTER Component Page Body Control Module . . . . . . . . . . . . . . . . . 8W-46-2 Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-46-2 Component Page Integrated Power Module . . . . . . . . . . . . . . 8W-46-2 Message Center . . . . . . . . . . . . . . . . . . . . . 8W-46-2 RS 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Accessory Relay . . . . . . . . . . . . . . . . . . . 8W-47-2, 5 Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5 Body Control Module . . . . . . . . . . . . . 8W-47-2, 5, 7 CD Changer . . . . . . . . . . . . . . . . . . . . . . . 8W-47-11 Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7 Diagnostic Junction Port . . . . . . . . . . . . . 8W-47-2, 5 Front Cigar Lighter . . . . . . . . . . . . . . . . 8W-47-2, 5 Front Control Module . . . . . . . . . . . . . 8W-47-2, 5, 6 Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 5 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 6 G202 . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 5, 9, 10 Integrated Power Module . . . . . . . . . . 8W-47-2, 5, 6 Left Door Speaker . . . . . . . . . . . . . . . . 8W-47-3, 8, 9 Component Page Left Instrument Panel Speaker . . . . . . . . 8W-47-3, 8 Left Rear Pillar Speaker . . . . . . . . . . . . . . 8W-47-10 Left Rear Speaker . . . . . . . . . . . . . . . 8W-47-4, 6, 10 Left Remote Radio Switch . . . . . . . . . . . . . . 8W-47-7 Name Brand Speaker Relay . . . . . . . . . . . . 8W-47-6 Radio . . . . . . . . . . . . . . 8W-47-2, 3, 4, 5, 6, 9, 10, 11 Radio Choke . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6 Right Door Speaker . . . . . . . . . . . . . . . 8W-47-3, 8, 9 Right Instrument Panel Speaker . . . . . . 8W-47-3, 8 Right Rear Pillar Speaker . . . . . . . . . . . . . 8W-47-10 Right Rear Speaker . . . . . . . . . . . . . . 8W-47-4, 6, 10 Right Remote Radio Switch . . . . . . . . . . . . 8W-47-7 8W-48 REAR WINDOW DEFOGGER RS 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component A/C- Heater Control . . Accessory Relay . . . . . Auto Temp Control . . . Defogger Relay . . . . . . Electric Wiper De-Icer . Front Control Module . Fuse 11 . . . . . . . . . . . . Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8W-48-2 8W-48-2 8W-48-2 8W-48-2 8W-48-2 8W-48-2 8W-48-2 8W-48-2 Component G200 . . . . . . . . . . . . . . . . . . G400 . . . . . . . . . . . . . . . . . . Integrated Power Module . . Left Power Mirror . . . . . . . . PTC 4 . . . . . . . . . . . . . . . . . Rear Window Defogger Grid Right Power Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8W-48-3 8W-48-2 8W-48-2 8W-48-3 8W-48-2 8W-48-2 8W-48-3 RS 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Ambient Temp Sensor . . . . . . . . . . . . . . . . . 8W-49-2 Automatic Day/Night Mirror . . . . . . . . . . 8W-49-3, 4 Body Control Module . . . . . . . . . . . . . 8W-49-2, 3, 4 Diagnostic Junction Port . . . . . . . . . . . . . . . 8W-49-4 Front Control Module . . . . . . . . . . . . . . . . . 8W-49-2 Front Reading Lamps/Switch . . . . . . . . . . . 8W-49-4 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2 Component Page G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-4 Integrated Power Module . . . . . . . . . . . . . . 8W-49-2 Left Power Mirror . . . . . . . . . . . . . . . . . . . . 8W-49-3 Name Brand Speaker Relay . . . . . . . . . . . . 8W-49-2 Overhead Console . . . . . . . . . . . . . . . . 8W-49-2, 3, 4 Radio Choke . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2 RS 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Body Control Module . . . . . . . . . . . . . 8W-50-2, 4, 5 Diagnostic Junction Port . . . . . . . . . . . 8W-50-5, 6, 8 Front Control Module . . 8W-50-3, 4, 6, 7, 8, 9, 10, 11 Front Fog Lamp Relay . . . . . . . . . . . . . . . 8W-50-11 Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11 Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 6 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 8 G102 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 8, 11 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 10 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3 Headlamp Switch . . . . . . . . . . . . . . . . . 8W-50-2, 10 Integrated Power Module . . . . . . . . . 8W-50-3, 4, 5, 6, 7, 8, 9, 10, 11 Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-11 Left Front Park/Turn Signal Lamp . . . . . . . 8W-50-4 Component Page Left Headlamp . . . . . . . . . . . . . . . . . . . . . . 8W-50-3 Left Headlamp Leveling Motor . . . . . . . 8W-50-6, 10 Left High Beam Lamp . . . . . . . . . . . . . . 8W-50-6, 7 Left Low Beam Lamp . . . . . . . . . . . . . . . . . 8W-50-7 Left Park Lamp . . . . . . . . . . . . . . . . . . . 8W-50-6, 7 Multi- Function Switch . . . . . . . . . . . . . . . . 8W-50-5 Park Lamp Relay . . . . . . . . . . . . . . . . 8W-50-4, 6, 8 Right Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-50-11 Right Front Park/Turn Signal Lamp . . . . . . 8W-50-4 Right Headlamp . . . . . . . . . . . . . . . . . . . . . 8W-50-3 Right Headlamp Leveling Motor . . . . . . 8W-50-8, 10 Right High Beam Lamp . . . . . . . . . . . . . 8W-50-8, 9 Right Low Beam Lamp . . . . . . . . . . . . . . . . 8W-50-9 Right Park Lamp . . . . . . . . . . . . . . . . . . 8W-50-8, 9 RS 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Back-Up Lamp Switch . . . . . . . . . . . . . . . . 8W-51-5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5 Body Control Module . . . . . . . . . . . . 8W-51-2, 3, 4, 5 Brake Lamp Switch . . . . . . . . . . . . . . . . 8W-51-2, 4 Center High Mounted Stop Lamp . . . . . . . . 8W-51-6 Front Control Module . . . . . . . . . . . . . 8W-51-2, 4, 5 Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 4 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 4, 5 Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 4 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5 G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5 Component Page G302 . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3, 4, 5 G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6 Integrated Power Module . . . . . . . . . . 8W-51-2, 4, 5 Left Rear Lamp Assembly . . . . . . . . 8W-51-2, 3, 4, 5 Left Stop/Turn Signal Relay . . . . . . . . . . . . 8W-51-3 License Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6 Park Lamp Relay . . . . . . . . . . . . . . . . 8W-51-2, 4, 5 Right Combination Relay . . . . . . . . . . . . . . 8W-51-3 Right Rear Lamp Assembly . . . . . . . . . 8W-51-2, 4, 5 Trailer Tow Connector . . . . . . . . . . . . . . . . . 8W-51-3 RS 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Body Control Module . . . . . . . . . . . . 8W-52-2, 3, 4, 6 Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-52-5 Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-6 G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4 Instrument Panel Switch Bank . . . . . . . . 8W-52-2, 3 Integrated Power Module . . . . . . . . . . 8W-52-2, 3, 6 Left Combination Relay . . . . . . . . . . . . . . . 8W-52-5 Left Front Park/Turn Signal Lamp . . . . . . . 8W-52-2 Left Rear Lamp Assembly . . . . . . . . . . . . . . 8W-52-4 Component Page Left Repeater Lamp . . . . . . . . . . . . . . . . . . 8W-52-6 Left Stop/Turn Signal Relay . . . . . . . . . . 8W-52-4, 5 Left Turn Signal Lamp . . . . . . . . . . . . . . . . 8W-52-3 Multi- Function Switch . . . . . . . . . . . . . . 8W-52-2, 3 Right Combination Relay . . . . . . . . . . . . 8W-52-4, 5 Right Front Park/Turn Signal Lamp . . . . . . 8W-52-2 Right Rear Lamp Assembly . . . . . . . . . . . . 8W-52-4 Right Repeater Lamp . . . . . . . . . . . . . . . . . 8W-52-6 Right Stop/Turn Signal Relay . . . . . . . . . . . 8W-52-5 Right Turn Signal Lamp . . . . . . . . . . . . . . . 8W-52-3 Trailer Tow Connector . . . . . . . . . . . . . . . . . 8W-52-5 RS 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Accessory Relay . . . . . . . . . . . . . . . . . . . . . 8W-53-3 Body Control Module . . . . . . . . . . . . . 8W-53-3, 5, 6 Diagnostic Junction Port . . . . . . . . . . . . . . . 8W-53-5 Front Control Module . . . . . . . . . . . 8W-53-2, 3, 4, 5 Front Washer Pump Motor . . . . . . . . . . . . . 8W-53-3 Front Wiper Hi/Low Relay . . . . . . . . . . . . . 8W-53-2 Front Wiper On/Off Relay . . . . . . . . . . . . . . 8W-53-2 Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3 Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4 Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3 G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4 Component Page G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-6 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3 Headlamp Washer Pump Motor . . . . . . . . . 8W-53-4 Headlamp Washer Relay . . . . . . . . . . . . . . . 8W-53-4 Instrument Panel Switch Bank . . . . . . . . . . 8W-53-6 Integrated Power Module . . . . . . . . 8W-53-2, 3, 4, 5 Multi- Function Switch . . . . . . . . . . . . . . . . 8W-53-5 Rear Washer Pump Motor . . . . . . . . . . . . . . 8W-53-3 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . 8W-53-3 Washer Fluid Level Switch . . . . . . . . . . . . . 8W-53-4 Wiper Module . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 8W-54 TRAILER TOW RS 8W - 54 - 1 8W-54 TRAILER TOW Component Body Control Module . . . Brake Lamp Switch . . . . Front Control Module . . . Fuse 2 . . . . . . . . . . . . . . . G302 . . . . . . . . . . . . . . . . Integrated Power Module Left Combination Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8W-54-2 8W-54-2 8W-54-2 8W-54-2 8W-54-2 8W-54-2 8W-54-3 Component Page Left Rear Lamp Assembly . . . . . . . . . . . . . . 8W-54-2 Left Stop/Turn Signal Relay . . . . . . . . . . 8W-54-2, 3 Park Lamp Relay . . . . . . . . . . . . . . . . . . . . 8W-54-2 Right Combination Relay . . . . . . . . . . . . 8W-54-2, 3 Right Stop/Turn Signal Relay . . . . . . . . . . . 8W-54-3 Trailer Tow Connector . . . . . . . . . . . . . . . 8W-54-2, 3 RS 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Accessory Relay . . . . . . . . . . . . . . . . . . . . . 8W-60-2 Driver Power Window Motor . . . . . . . . 8W-60-3, 4, 6 Driver Power Window Switch . . . 8W-60-3, 4, 5, 6, 7 Front Control Module . . . . . . . . . . . . . . . . . 8W-60-2 Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3, 4, 7 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-5, 6 Component Page Integrated Power Module . . . . . . . . . . . . . . 8W-60-2 Left Rear Vent Motor . . . . . . . . . . . . . . . 8W-60-3, 6 Passenger Power Window Motor . . . . . . . 8W-60-5, 7 Passenger Power Window Switch . . . . . . 8W-60-5, 7 Power Window Circuit Breaker . . . . . . . . . . 8W-60-2 Power Window Switch . . . . . . . . . . . . . . . 8W-60-4, 5 Right Rear Vent Motor . . . . . . . . . . . . . . 8W-60-3, 6 RS 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Accessory Relay . . . . . . . . . . . . . . . . 8W-61-2, 3, 4, 7 Body Control Module . . . . . . . 8W-61-2, 3, 4, 5, 6, 7, 10, 13, 14, 15, 16, 19 Diagnostic Junction Port . . . . . . . . . 8W-61-7, 10, 16 Driver Door Lock Switch . . . . . . . . . . . 8W-61-2, 3, 4 Front Control Module . . . . . . . . . . . . . . . . . 8W-61-7 Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4, 7 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-6 Fuse 19 . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 13, 14 Fuse 20 . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 13, 14 Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3 Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-7 Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-16 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-6 G300 . . . . . . . . . . . . . . . 8W-61-2, 3, 4, 5, 7, 8, 9, 14 G301 . . . . . . . . . . . . . 8W-61-2, 3, 4, 5, 10, 11, 12, 14 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-16 G400 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-15, 19 Integrated Power Module . . . . . . . . 8W-61-2, 3, 4, 5, 6, 7, 13, 14, 16 Left B-Pillar Switch . . . . . . . . . . . . . . . . . . 8W-61-7 Left Cinch/Release Motor . . . . . . . . . . . . . . 8W-61-8 Left Front Door Lock Motor/Ajar Switch . . . 8W-61-5 Left Full Open Switch . . . . . . . . . . . . . . . . . 8W-61-8 Left Sliding Door Control Module . 8W-61-7, 8, 9, 13 Left Sliding Door Latch Sensing Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-7, 9 Left Sliding Door Lock Motor . . . . . . . . . . 8W-61-13 Component Page Left Sliding Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-14 Left Sliding Door Motor . . . . . . . . . . . . . . . 8W-61-8 License Lamp . . . . . . . . . . . . . . . . . . . 8W-61-18, 19 Liftgate Ajar Switch . . . . . . . . . . . . . . . . . 8W-61-15 Liftgate Cinch/Release Motor . . . . . . . . . . 8W-61-18 Liftgate Left Pinch Sensor . . . . . . . . . . . . 8W-61-18 Liftgate Right Pinch Sensor . . . . . . . . . . . 8W-61-18 Passenger Door Lock Switch . . . . . . . . 8W-61-2, 3, 4 Power Liftgate Module . . . . . . . 8W-61-16, 17, 18, 19 Power Liftgate Motor . . . . . . . . . . . . . . . . 8W-61-17 Power Window Circuit Breaker . . . . . . . . 8W-61-2, 3 Remote Keyless Entry Antenna . . . . . . . . . 8W-61-6 Remote Keyless Entry Module . . . . . . . . . . 8W-61-6 Right B-Pillar Switch . . . . . . . . . . . . . . 8W-61-7, 10 Right Cinch/Release Motor . . . . . . . . . . . . 8W-61-11 Right Front Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5 Right Full Open Switch . . . . . . . . . . . . . . . 8W-61-11 Right Sliding Door Control Module . . . . . . . . . . . . . . . . . 8W-61-10, 11, 12, 13 Right Sliding Door Latch Sensing Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-61-10, 12 Right Sliding Door Lock Motor . . . . . . . . . 8W-61-13 Right Sliding Door Lock Motor/Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-14 Right Sliding Door Motor . . . . . . . . . . . . . 8W-61-11 RS 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Automatic Day/Night Mirror . . . . . . . . . . . . 8W-62-8 Body Control Module . . . . . . . . . . 8W-62-2, 3, 4, 5, 9 Defogger Relay . . . . . . . . . . . . . . . . . . . . . 8W-62-10 Diagnostic Junction Port . . . . . . . . . . . . . . . 8W-62-3 Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 4, 5 Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3 G200 . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3, 4, 5, 10 Integrated Power Module . . . 8W-62-2, 3, 4, 5, 9, 10 Left Power Mirror . . . . . . . . . 8W-62-2, 4, 7, 8, 9, 10 Component Page Memory Seat/Mirror Module . . . . . . 8W-62-3, 6, 7, 8 Memory Set Switch . . . . . . . . . . . . . . . . . . . 8W-62-3 Passenger Folding Mirror Relay . . . . . . . 8W-62-2, 9 Power Folding Mirror Switch . . . . . . . . . . . 8W-62-2 Power Mirror Switch . . . . . . . . . . . . 8W-62-2, 4, 5, 6 Power Seat Circuit Breaker . . . . . . . . . . . . 8W-62-3 PTC 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-10 Right Power Mirror . . . . . . . . . . 8W-62-2, 5, 7, 9, 10 RS 8W-63 POWER SEATS 8W - 63 - 1 8W-63 POWER SEATS Component Page Body Control Module . . . . . . . . . . . . . . . 8W-63-5, 9 Diagnostic Junction Port . . . . . . . . . . . . . . . 8W-63-5 Driver Heated Seat Back . . . . . . . . . . . . . . 8W-63-9 Driver Heated Seat Cushion . . . . . . . . . . . . 8W-63-9 Driver Heated Seat Module . . . . . . . . . 8W-63-3, 4, 9 Driver Power Seat Front Riser Motor . . . 8W-63-2, 7 Driver Power Seat Front Riser Position Sensor . . . . . . . . . . . . . . . . . . . . 8W-63-8 Driver Power Seat Horizontal Motor . . . . 8W-63-2, 7 Driver Power Seat Horizontal Position Sensor . . . . . . . . . . . . . . . . . . . . 8W-63-8 Driver Power Seat Rear Riser Motor . . . 8W-63-2, 7 Driver Power Seat Rear Riser Position Sensor . . . . . . . . . . . . . . . . . . . . 8W-63-8 Driver Power Seat Recliner Motor . . . . . 8W-63-2, 7 Driver Power Seat Recliner Position Sensor . . . . . . . . . . . . . . . . . . . . 8W-63-8 Component Page Driver Power Seat Switch . . . . . . . . . . . . 8W-63-2, 6 Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 4 G200 . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 4, 6, 9 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-3, 10 Instrument Panel Switch Bank . . . . . . . . . . 8W-63-9 Integrated Power Module . . . . . . . . . . . . 8W-63-2, 4 Memory Seat/Mirror Module . . . . 8W-63-4, 5, 6, 7, 8 Memory Set Switch . . . . . . . . . . . . . . . . . . . 8W-63-5 Passenger Heated Seat Back . . . . . . . . . . . 8W-63-10 Passenger Heated Seat Cushion . . . . . . . . 8W-63-10 Passenger Heated Seat Module . . . . . . . . . 8W-63-10 Passenger Power Seat Front Riser Motor . . 8W-63-3 Passenger Power Seat Horizontal Motor . . . 8W-63-3 Passenger Power Seat Rear Riser Motor . . . 8W-63-3 Passenger Power Seat Recliner Motor . . . . 8W-63-3 Passenger Power Seat Switch . . . . . . . . . . . 8W-63-3 Power Seat Circuit Breaker . . . . . . . . 8W-63-2, 3, 4 RS 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-15 S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 3 S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6 S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 8 S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-42, 45 S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3 S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3 S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6 S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41 S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2 S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-40 S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5 S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4, 5 S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4 S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2 S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8 S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5 S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35 S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41 S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2 S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28 S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28 S129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-54 S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-60 S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-27 S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28 S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-18 S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-26 S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6 S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43 S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-47 S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43 S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 S148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5 S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-65 S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-18 S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-61 S157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-25 S177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 S179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 S187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20 S188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43 S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-39 S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-19 S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-17 S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-38 S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7 S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-50 S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5 S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10 S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5 S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-45, 47 S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7 Component Page S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7 S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5 S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35 S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-65 S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8 S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6 S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8 S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-61 S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-13 S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6 S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27, 28 S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6 S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-10 S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-51 S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-39 S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-6 S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5 S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-67 S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30 S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32 S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25 S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31 S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-44, 47 S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12 S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5 S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23 S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-15 S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23 S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6 S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6 S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-11 S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9 S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3 S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21 S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-13 S339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21 S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30 S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20 S343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15 S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-9 S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19 S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-33, 34 S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19 S348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14 S349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-9 S350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14 S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23 S353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-24 S354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28 S355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22 S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-50 S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 S362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-48 S363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8 S364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20 S365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16 S366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-49 S368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-47 S370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-45 S371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15 RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page A/C Compressor Clutch . . . . . . . . . . . . . . . . 8W-80-6 A/C Pressure Sensor . . . . . . . . . . . . . . . . . . 8W-80-6 A/C-Heater Control C1 (MTC) . . . . . . . . . . . 8W-80-6 A/C-Heater Control C2 (MTC) . . . . . . . . . . . 8W-80-7 Accelerator Pedal Position Sensor (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7 Adjustable Pedals Module (Except Built-Up-Export) . . . . . . . . . . . . 8W-80-7 Adjustable Pedals Switch (Except Built-Up-Export) . . . . . . . . . . . . 8W-80-7 Airbag Control Module (ORC) . . . . . . . . . . . 8W-80-8 Ambient Temp Sensor (Except Base) . . . . . 8W-80-8 ATC Remote Sensor (ATC) . . . . . . . . . . . . . 8W-80-8 Auto Temp Control C1 . . . . . . . . . . . . . . . . 8W-80-9 Auto Temp Control C2 . . . . . . . . . . . . . . . . 8W-80-9 Auto Temp Control C3 . . . . . . . . . . . . . . . . 8W-80-9 Automatic Day/Night Mirror (Premium/Luxury) . . . . . . . . . . . . . . . . . 8W-80-9 Autostick Switch (Except Built-Up-Export) . . . . . . . . . . . . . . . . . . 8W-80-10 Back-Up Lamp Switch (MTX) . . . . . . . . . . 8W-80-10 Battery Temperature Sensor (Diesel) . . . . 8W-80-10 Blower Motor Resistor C1 (MTC) . . . . . . . 8W-80-10 Blower Motor Resistor C2 (MTC) . . . . . . . 8W-80-10 Body Control Module C1 . . . . . . . . . . . . . . 8W-80-11 Body Control Module C2 . . . . . . . . . . . . . . 8W-80-11 Body Control Module C3 . . . . . . . . . . . . . . 8W-80-12 Body Control Module C4 . . . . . . . . . . . . . . 8W-80-13 Body Control Module C5 . . . . . . . . . . . . . . 8W-80-14 Boost Pressure Sensor (Diesel) . . . . . . . . . 8W-80-14 Brake Fluid Level Switch . . . . . . . . . . . . . 8W-80-14 Brake Lamp Switch . . . . . . . . . . . . . . . . . 8W-80-15 Brake Transmission Shift Interlock Solenoid (EATX) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 C101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 C101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 C102 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 C102 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 C102 (3.3L/3.8L) . . . . . . . . . . . . . . . . . . . . 8W-80-17 C102 (3.3L/3.8L) . . . . . . . . . . . . . . . . . . . . 8W-80-18 C103 (Diesel) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18 C103 (Diesel) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18 C106 (Built-Up-Export) . . . . . . . . . . . . . . . 8W-80-18 C106 (Built-Up-Export) . . . . . . . . . . . . . . . 8W-80-19 C107 (Built-Up-Export) . . . . . . . . . . . . . . . 8W-80-19 C107 (Built-Up-Export) . . . . . . . . . . . . . . . 8W-80-19 C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20 C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22 C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23 C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24 Component C202 . . . . . . . . . . . . . . . . . . . . . . . C202 . . . . . . . . . . . . . . . . . . . . . . . C203 (United Kingdom) . . . . . . . . C203 (United Kingdom) . . . . . . . . C300 (LHD) . . . . . . . . . . . . . . . . . . C300 (LHD) . . . . . . . . . . . . . . . . . . C300 (RHD) . . . . . . . . . . . . . . . . . C300 (RHD) . . . . . . . . . . . . . . . . . C301 . . . . . . . . . . . . . . . . . . . . . . . C301 . . . . . . . . . . . . . . . . . . . . . . . C302 . . . . . . . . . . . . . . . . . . . . . . . C302 . . . . . . . . . . . . . . . . . . . . . . . C303 (LHD) . . . . . . . . . . . . . . . . . . C303 (LHD) . . . . . . . . . . . . . . . . . . C303 (RHD) . . . . . . . . . . . . . . . . . C303 (RHD) . . . . . . . . . . . . . . . . . C304 . . . . . . . . . . . . . . . . . . . . . . . C304 . . . . . . . . . . . . . . . . . . . . . . . C305 . . . . . . . . . . . . . . . . . . . . . . . C305 . . . . . . . . . . . . . . . . . . . . . . . C306 . . . . . . . . . . . . . . . . . . . . . . . C306 . . . . . . . . . . . . . . . . . . . . . . . C307 . . . . . . . . . . . . . . . . . . . . . . . C307 . . . . . . . . . . . . . . . . . . . . . . . C308 . . . . . . . . . . . . . . . . . . . . . . . C308 . . . . . . . . . . . . . . . . . . . . . . . C309 . . . . . . . . . . . . . . . . . . . . . . . C309 . . . . . . . . . . . . . . . . . . . . . . . C310 (Front Console) . . . . . . . . . . C310 (Front Console) . . . . . . . . . . C311 . . . . . . . . . . . . . . . . . . . . . . . C311 . . . . . . . . . . . . . . . . . . . . . . . C312 . . . . . . . . . . . . . . . . . . . . . . . C312 . . . . . . . . . . . . . . . . . . . . . . . C313 (Rear Console) . . . . . . . . . . . C313 (Rear Console) . . . . . . . . . . . C314 (High Line) . . . . . . . . . . . . . C314 (High Line) . . . . . . . . . . . . . C315 (High Line) . . . . . . . . . . . . . C315 (High Line) . . . . . . . . . . . . . C316 (Power Sliding Door) . . . . . . C316 (Power Sliding Door) . . . . . . C317 (Power Sliding Door) . . . . . . C317 (Power Sliding Door) . . . . . . C318 (Trailer Tow) . . . . . . . . . . . . C318 (Trailer Tow) . . . . . . . . . . . . C319 (Except Built-Up-Export/Low C319 (Except Built-Up-Export/Low C320 . . . . . . . . . . . . . . . . . . . . . . . C320 . . . . . . . . . . . . . . . . . . . . . . . C321 . . . . . . . . . . . . . . . . . . . . . . . C321 . . . . . . . . . . . . . . . . . . . . . . . ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... Line) Line) ..... ..... ..... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8W-80-24 8W-80-24 8W-80-24 8W-80-25 8W-80-25 8W-80-25 8W-80-26 8W-80-26 8W-80-26 8W-80-26 8W-80-27 8W-80-27 8W-80-27 8W-80-28 8W-80-28 8W-80-28 8W-80-29 8W-80-29 8W-80-29 8W-80-29 8W-80-30 8W-80-30 8W-80-30 8W-80-30 8W-80-31 8W-80-31 8W-80-31 8W-80-32 8W-80-32 8W-80-32 8W-80-32 8W-80-33 8W-80-33 8W-80-34 8W-80-34 8W-80-34 8W-80-35 8W-80-35 8W-80-35 8W-80-36 8W-80-36 8W-80-36 8W-80-36 8W-80-37 8W-80-37 8W-80-37 8W-80-37 8W-80-38 8W-80-38 8W-80-38 8W-80-38 8W-80-38 8W - 80 - 2 Component C322 (Memory) . . . . . . . . . . . . . . . . . . . C322 (Memory) . . . . . . . . . . . . . . . . . . . C324 (Manual Sliding Door) . . . . . . . . . C324 (Manual Sliding Door) . . . . . . . . . C325 (Manual Sliding Door) . . . . . . . . . C325 (Manual Sliding Door) . . . . . . . . . C326 . . . . . . . . . . . . . . . . . . . . . . . . . . . C326 . . . . . . . . . . . . . . . . . . . . . . . . . . . C327 . . . . . . . . . . . . . . . . . . . . . . . . . . . C327 . . . . . . . . . . . . . . . . . . . . . . . . . . . C329 (Diesel) . . . . . . . . . . . . . . . . . . . . . C329 (Diesel) . . . . . . . . . . . . . . . . . . . . . C330 (Diesel) . . . . . . . . . . . . . . . . . . . . . C330 (Diesel) . . . . . . . . . . . . . . . . . . . . . C331 (Diesel) . . . . . . . . . . . . . . . . . . . . . C331 (Diesel) . . . . . . . . . . . . . . . . . . . . . C332 (ATC) . . . . . . . . . . . . . . . . . . . . . . C332 (ATC) . . . . . . . . . . . . . . . . . . . . . . Cabin Heater Assist C1 (Diesel) . . . . . . Cabin Heater Assist C2 (Diesel) . . . . . . Camshaft Position Sensor (Diesel) . . . . Camshaft Position Sensor (Gas) . . . . . . CD Changer . . . . . . . . . . . . . . . . . . . . . Center Dome Lamp (Base/High Line) . . Center High Mounted Stop Lamp . . . . . Clockspring C1 . . . . . . . . . . . . . . . . . . . Clockspring C2 . . . . . . . . . . . . . . . . . . . Clockspring C3 . . . . . . . . . . . . . . . . . . . Clockspring C4 . . . . . . . . . . . . . . . . . . . Clockspring C5 . . . . . . . . . . . . . . . . . . . Clutch Pedal Interlock Switch (MTX) . . Clutch Pedal Interlock Switch Jumper (ATX) . . . . . . . . . . . . . . . . . . . . . . . . Clutch Pedal Upstop Switch (Diesel) . . . Controller Antilock Brake . . . . . . . . . . . Crank Case Ventilation Heater (Diesel) Crankshaft Position Sensor (Diesel) . . . Crankshaft Position Sensor (Gas) . . . . . Data Link Connector . . . . . . . . . . . . . . . Diagnostic Junction Port . . . . . . . . . . . . Dosing Pump (Diesel) . . . . . . . . . . . . . . Driver Airbag C1 . . . . . . . . . . . . . . . . . . Driver Airbag C2 . . . . . . . . . . . . . . . . . . Driver Blend Door Actuator (ATC) . . . . Driver Blend Door Actuator (MTC) . . . . Driver Door Courtesy Lamp . . . . . . . . . Driver Door Lock Switch . . . . . . . . . . . . Driver Heated Seat Back . . . . . . . . . . . Driver Heated Seat Cushion . . . . . . . . . Driver Heated Seat Module C1 . . . . . . . Driver Heated Seat Module C2 . . . . . . . Driver Heated Seat Module C3 . . . . . . . Driver Power Seat Front Riser Motor . . 8W-80 CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8W-80-39 8W-80-39 8W-80-39 8W-80-40 8W-80-40 8W-80-40 8W-80-40 8W-80-40 8W-80-40 8W-80-41 8W-80-41 8W-80-41 8W-80-41 8W-80-41 8W-80-42 8W-80-42 8W-80-42 8W-80-42 8W-80-42 8W-80-43 8W-80-43 8W-80-43 8W-80-43 8W-80-43 8W-80-44 8W-80-44 8W-80-44 8W-80-44 8W-80-44 8W-80-45 8W-80-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-45 8W-80-45 8W-80-46 8W-80-46 8W-80-46 8W-80-47 8W-80-47 8W-80-47 8W-80-48 8W-80-48 8W-80-48 8W-80-48 8W-80-48 8W-80-49 8W-80-49 8W-80-49 8W-80-49 8W-80-49 8W-80-50 8W-80-50 8W-80-50 Component Driver Power Seat Front Riser Position Sensor . . . . . . . . . . . . . . . . . Driver Power Seat Horizontal Motor . . . Driver Power Seat Horizontal Position Sensor . . . . . . . . . . . . . . . . . Driver Power Seat Rear Riser Motor . . Driver Power Seat Rear Riser Position Sensor . . . . . . . . . . . . . . . . . Driver Power Seat Recliner Motor . . . . Driver Power Seat Recliner Position Sensor . . . . . . . . . . . . . . . . . Driver Power Seat Switch . . . . . . . . . . . Driver Power Window Motor . . . . . . . . . Driver Power Window Switch (Except Lowline) . . . . . . . . . . . . . . . . Driver Power Window Switch (Lowline) Driver Power Window Switch (RHD) . . Driver Seat Belt Switch . . . . . . . . . . . . Driver Seat Belt Tensioner . . . . . . . . . . EGR Solenoid (Diesel) . . . . . . . . . . . . . . EGR Solenoid (Gas) . . . . . . . . . . . . . . . Electric Wiper De-Icer C1 . . . . . . . . . . . Electric Wiper De-Icer C2 . . . . . . . . . . . Engine Control Module C1 (Diesel) . . . . Engine Control Module C2 (Diesel) . . . . Engine Coolant Temp Sensor (Diesel) . . Engine Coolant Temp Sensor (Gas) . . . . Engine Oil Pressure Sensor (Diesel) . . . Engine Oil Pressure Switch (Gas) . . . . . Engine Oil Temperature Sensor (Diesel) EVAP/Purge Solenoid (Gas) . . . . . . . . . . Evaporator Temperature Sensor . . . . . . Floor Console Lamp . . . . . . . . . . . . . . . Floor Console Power Outlet . . . . . . . . . Front Blower Module C1 (ATC) . . . . . . . Front Blower Module C2 (ATC) . . . . . . . Front Cigar Lighter . . . . . . . . . . . . . . . Front Reading Lamps/Switch . . . . . . . . Front Washer Pump Motor . . . . . . . . . . Fuel Heater (Diesel) . . . . . . . . . . . . . . . Fuel Injector No. 1 (2.4L/3.3L/3.8L) . . . Fuel Injector No. 1 (Diesel) . . . . . . . . . . Fuel Injector No. 2 (2.4L/3.3L/3.8L) . . . Fuel Injector No. 2 (Diesel) . . . . . . . . . . Fuel Injector No. 3 (2.4L/3.3L/3.8L) . . . Fuel Injector No. 3 (Diesel) . . . . . . . . . . Fuel Injector No. 4 (2.4L/3.3L/3.8L) . . . Fuel Injector No. 4 (Diesel) . . . . . . . . . . Fuel Injector No. 5 (3.3L/3.8L) . . . . . . . Fuel Injector No. 6 (3.3L/3.8L) . . . . . . . Fuel Pressure Sensor (Diesel) . . . . . . . . Fuel Pressure Solenoid (Diesel) . . . . . . . Fuel Pump Module . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . . . . . . . . . . RS Page . . 8W-80-50 . . 8W-80-50 . . 8W-80-51 . . 8W-80-51 . . 8W-80-51 . . 8W-80-51 . . 8W-80-51 . . 8W-80-52 . . 8W-80-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52 8W-80-53 8W-80-53 8W-80-53 8W-80-53 8W-80-54 8W-80-54 8W-80-54 8W-80-54 8W-80-55 8W-80-57 8W-80-57 8W-80-58 8W-80-58 8W-80-58 8W-80-58 8W-80-58 8W-80-59 8W-80-59 8W-80-59 8W-80-59 8W-80-59 8W-80-60 8W-80-60 8W-80-60 8W-80-60 8W-80-60 8W-80-61 8W-80-61 8W-80-61 8W-80-61 8W-80-61 8W-80-62 8W-80-62 8W-80-62 8W-80-62 8W-80-62 8W-80-63 8W-80-63 8W-80-63 RS 8W-80 CONNECTOR PIN-OUTS Component Glove Box Lamp . . . . . . . . . . . . . . . . . . . Glow Plug Relay (Diesel) . . . . . . . . . . . . . Halo Lamp . . . . . . . . . . . . . . . . . . . . . . . Headlamp Switch . . . . . . . . . . . . . . . . . . Headlamp Washer Pump Motor (Built-Up-Export) . . . . . . . . . . . . . . . . High Note Horn . . . . . . . . . . . . . . . . . . . Hood Ajar Switch . . . . . . . . . . . . . . . . . . Idle Air Control Motor (2.4L) . . . . . . . . . Idle Air Control Motor (3.3L/3.8L) . . . . . . Ignition Coil (2.4L) . . . . . . . . . . . . . . . . . Ignition Coil (3.3L/3.8L) . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . Inlet Air Temperature Sensor . . . . . . . . . Input Speed Sensor (EATX) . . . . . . . . . . Instrument Cluster . . . . . . . . . . . . . . . . . Instrument Panel Switch Bank . . . . . . . . Integrated Power Module C1 . . . . . . . . . Integrated Power Module C2 . . . . . . . . . Integrated Power Module C3 (Diesel) . . . Integrated Power Module C3 (Gas) . . . . . Integrated Power Module C4 . . . . . . . . . Integrated Power Module C5 . . . . . . . . . Integrated Power Module C6 . . . . . . . . . Integrated Power Module C7 . . . . . . . . . Integrated Power Module C8 . . . . . . . . . Integrated Power Module C9 . . . . . . . . . Knock Sensor (2.4L) . . . . . . . . . . . . . . . . Knock Sensor (3.3L/3.8L) (Except Built-Up-Export) . . . . . . . . . . . . . . . . . Leak Detection Pump (Except Built-Up-Export) . . . . . . . . . . . . . . . . . Left B-Pillar Switch (Power Sliding Door) . . . . . . . . . . . . . . . . . . . . Left Cinch/Release Motor (Power Sliding Door) . . . . . . . . . . . . . . . . . . . . Left Combination Relay (Trailer Tow) . . . Left Cylinder Lock Switch . . . . . . . . . . . . Left Door Speaker . . . . . . . . . . . . . . . . . . Left Fog Lamp (Built-Up-Export) . . . . . . Left Fog Lamp (Except Built-Up-Export) . . . . . . . . . . . . . . . . . Left Front Door Ajar Switch (Base) . . . . . Left Front Door Lock Motor/Ajar Switch (Except Base) . . . . . . . . . . . . . . . . . . . Left Front Park/Turn Signal Lamp (Except Built-Up-Export) . . . . . . . . . . Left Front Wheel Speed Sensor . . . . . . . . Left Full Open Switch (Power Sliding Door) . . . . . . . . . . . . . . Left Headlamp (Except Built-Up-Export) Left Headlamp Leveling Motor (Built-Up-Export) . . . . . . . . . . . . . . . . Left High Beam Lamp (Built-Up-Export) . . . . . . . . . . . . . . . . . . . . Page 8W-80-63 8W-80-63 8W-80-63 8W-80-64 . . . . . . . . . . . . . . . . . . . . . . . 8W-80-64 8W-80-64 8W-80-64 8W-80-64 8W-80-65 8W-80-65 8W-80-65 8W-80-65 8W-80-65 8W-80-66 8W-80-66 8W-80-66 8W-80-67 8W-80-67 8W-80-68 8W-80-68 8W-80-69 8W-80-69 8W-80-69 8W-80-70 8W-80-70 8W-80-71 8W-80-71 . 8W-80-71 . 8W-80-71 . 8W-80-72 . . . . . 8W-80-72 8W-80-72 8W-80-72 8W-80-72 8W-80-73 . 8W-80-73 . 8W-80-73 . 8W-80-73 . 8W-80-73 . 8W-80-74 . 8W-80-74 . 8W-80-74 . 8W-80-74 . 8W-80-74 8W - 80 - 3 Component Left Instrument Panel Speaker . . . . . . . . . Left Liftgate Flood Lamp . . . . . . . . . . . . . Left Low Beam Lamp (Built-Up-Export) . . Left Mid Reading Lamp (Premium/Luxury) . . . . . . . . . . . . . . . . . Left Park Lamp (Built-Up-Export) . . . . . . Left Power Mirror . . . . . . . . . . . . . . . . . . . Left Rear Lamp Assembly . . . . . . . . . . . . . Left Rear Pillar Speaker . . . . . . . . . . . . . . Left Rear Reading Lamp (Luxury) . . . . . . Left Rear Speaker . . . . . . . . . . . . . . . . . . . Left Rear Vent Motor . . . . . . . . . . . . . . . . Left Rear Wheel Speed Sensor . . . . . . . . . Left Remote Radio Switch . . . . . . . . . . . . . Left Repeater Lamp (Built-Up-Export) . . . Left Seat Airbag . . . . . . . . . . . . . . . . . . . . Left Side Impact Airbag Control Module . . Left Sliding Door Control Module C1 (Power Sliding Door) . . . . . . . . . . . . . . . Left Sliding Door Control Module C2 (Power Sliding Door) . . . . . . . . . . . . . . . Left Sliding Door Latch Sensing Switch (Power Sliding Door) . . . . . . . . . . . . . . . Left Sliding Door Lock Motor (Power Sliding Door) . . . . . . . . . . . . . . . Left Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) . . . . . . . . . . . . . . Left Sliding Door Motor (Power Sliding Door) . . . . . . . . . . . . . . . Left Speed Control Switch . . . . . . . . . . . . Left Stop/Turn Signal Relay (Trailer Tow) . Left Turn Signal Lamp (Built-Up-Export) . Left Visor/Vanity Lamp (Premium/Luxury) . . . . . . . . . . . . . . . . . License Lamp (Manual Release) . . . . . . . . License Lamp (Power Liftgate) . . . . . . . . . License Lamp (Power Release) . . . . . . . . . Lift Pump Motor (Diesel) . . . . . . . . . . . . . Liftgate Ajar Switch (Manual Release) . . . Liftgate Ajar Switch (Power Release) . . . . Liftgate Cinch/Release Motor (Power Liftgate) . . . . . . . . . . . . . . . . . . Liftgate Cylinder Lock Switch . . . . . . . . . . Liftgate Left Pinch Sensor (Power Liftgate) . . . . . . . . . . . . . . . . . . Liftgate Right Pinch Sensor (Power Liftgate) . . . . . . . . . . . . . . . . . . Low Note Horn . . . . . . . . . . . . . . . . . . . . . Manifold Absolute Pressure Sensor (Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . Mass Air Flow Sensor (Diesel) . . . . . . . . . Memory Seat/Mirror Module C1 . . . . . . . . Memory Seat/Mirror Module C2 . . . . . . . . Memory Seat/Mirror Module C3 . . . . . . . . Memory Seat/Mirror Module C4 . . . . . . . . Page 8W-80-75 8W-80-75 8W-80-75 8W-80-75 8W-80-75 8W-80-76 8W-80-76 8W-80-76 8W-80-76 8W-80-77 8W-80-77 8W-80-77 8W-80-77 8W-80-77 8W-80-78 8W-80-78 8W-80-78 8W-80-78 8W-80-79 8W-80-79 8W-80-79 8W-80-79 8W-80-79 8W-80-80 8W-80-80 8W-80-80 8W-80-80 8W-80-80 8W-80-81 8W-80-81 8W-80-81 8W-80-81 8W-80-81 8W-80-82 8W-80-82 8W-80-82 8W-80-82 8W-80-82 8W-80-83 8W-80-83 8W-80-84 8W-80-84 8W-80-84 8W - 80 - 4 Component Memory Set Switch . . . . . . . . . . . . . . . . . Message Center (High Line) . . . . . . . . . . Mode Door Actuator (ATC) . . . . . . . . . . . Mode Door Actuator (MTC) . . . . . . . . . . . Multi-Function Switch . . . . . . . . . . . . . . Output Speed Sensor (EATX) . . . . . . . . . Overhead Console (Except Base) . . . . . . . Oxygen Sensor 1/1 Upstream (Gas) . . . . . Oxygen Sensor 1/2 Downstream (Gas) . . Park/Neutral Position Switch (ATX) . . . . Passenger Airbag . . . . . . . . . . . . . . . . . . Passenger Blend Door Actuator (ATC) . . Passenger Blend Door Actuator (MTC) . . Passenger Door Courtesy Lamp . . . . . . . Passenger Door Lock Switch . . . . . . . . . . Passenger Folding Mirror Relay (Built-Up-Export) . . . . . . . . . . . . . . . . Passenger Heated Seat Back . . . . . . . . . . Passenger Heated Seat Cushion . . . . . . . Passenger Heated Seat Module C1 . . . . . Passenger Heated Seat Module C2 . . . . . Passenger Heated Seat Module C3 . . . . . Passenger Power Seat Front Riser Motor Passenger Power Seat Horizontal Motor . Passenger Power Seat Rear Riser Motor . Passenger Power Seat Recliner Motor . . . Passenger Power Seat Switch . . . . . . . . . Passenger Power Window Motor . . . . . . . Passenger Power Window Switch . . . . . . Passenger Seat Belt Switch . . . . . . . . . . Passenger Seat Belt Tensioner . . . . . . . . Power Folding Mirror Switch (Built-Up-Export) . . . . . . . . . . . . . . . . Power Liftgate Module C1 . . . . . . . . . . . Power Liftgate Module C2 . . . . . . . . . . . Power Liftgate Motor . . . . . . . . . . . . . . . Power Mirror Switch . . . . . . . . . . . . . . . . Power Outlet . . . . . . . . . . . . . . . . . . . . . . Power Seat Circuit Breaker (30A) . . . . . . Power Window Circuit Breaker (25A) . . . Power Window Switch (Lowline) . . . . . . . Powertrain Control Module C1 (Gas) . . . Powertrain Control Module C2 (Gas) . . . Radiator Fan No. 1 (Diesel) . . . . . . . . . . Radiator Fan No. 1 (Gas) . . . . . . . . . . . . Radiator Fan No. 2 (Diesel) . . . . . . . . . . Radiator Fan No. 2 (Gas) . . . . . . . . . . . . Radiator Fan Relay (Gas) . . . . . . . . . . . . Radiator Fan Relay No. 1 (Diesel) . . . . . . Radiator Fan Relay No. 2 (Diesel) . . . . . . Radiator Fan Relay No. 3 (Diesel) . . . . . . Radio C1 . . . . . . . . . . . . . . . . . . . . . . . . . Radio C2 . . . . . . . . . . . . . . . . . . . . . . . . . Radio Choke . . . . . . . . . . . . . . . . . . . . . . 8W-80 CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . Page 8W-80-84 8W-80-85 8W-80-85 8W-80-85 8W-80-85 8W-80-86 8W-80-86 8W-80-86 8W-80-87 8W-80-87 8W-80-87 8W-80-87 8W-80-87 8W-80-88 8W-80-88 . . . . . . . . . . . . . . . 8W-80-88 8W-80-88 8W-80-88 8W-80-89 8W-80-89 8W-80-89 8W-80-89 8W-80-90 8W-80-90 8W-80-90 8W-80-90 8W-80-90 8W-80-91 8W-80-91 8W-80-91 . . . . . . . . . . . . . . . . . . . . . . 8W-80-91 8W-80-92 8W-80-92 8W-80-92 8W-80-93 8W-80-93 8W-80-93 8W-80-93 8W-80-94 8W-80-94 8W-80-95 8W-80-96 8W-80-96 8W-80-96 8W-80-96 8W-80-96 8W-80-97 8W-80-97 8W-80-97 8W-80-98 8W-80-98 8W-80-99 RS Component Page Rear A/C-Heater Unit (3 Zone HVAC) . . . . 8W-80-99 Rear Auto Temp Control Switch (ATC) . . . 8W-80-99 Rear Blower Front Control Switch (3 Zone HVAC) . . . . . . . . . . . . . . . . . . . 8W-80-99 Rear Blower Motor Power Module C1 (ATC) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-100 Rear Blower Motor Power Module C2 (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-100 Rear Blower Rear Control Switch C1 (3 Zone HVAC) . . . . . . . . . . . . . . . . . . 8W-80-100 Rear Blower Rear Control Switch C2 (3 Zone HVAC) . . . . . . . . . . . . . . . . . . 8W-80-100 Rear Dome Lamp (Except Luxury) . . . . . 8W-80-100 Rear Mode Motor (ATC) . . . . . . . . . . . . . 8W-80-101 Rear Power Outlet . . . . . . . . . . . . . . . . . 8W-80-101 Rear Temperature Motor (ATC) . . . . . . . . 8W-80-101 Rear Washer Pump Motor . . . . . . . . . . . . 8W-80-101 Rear Wiper Motor . . . . . . . . . . . . . . . . . . 8W-80-101 Recirculation Door Actuator (ATC) . . . . . 8W-80-102 Recirculation Door Actuator (MTC) . . . . . 8W-80-102 Remote Keyless Entry Antenna (Japan) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-102 Remote Keyless Entry Module . . . . . . . . 8W-80-102 Right B-Pillar Switch (Power Sliding Door) . . . . . . . . . . . . . . 8W-80-102 Right Cinch/Release Motor (Power Sliding Door) . . . . . . . . . . . . . . 8W-80-103 Right Combination Relay (Trailer Tow) . . 8W-80-103 Right Cylinder Lock Switch . . . . . . . . . . 8W-80-103 Right Door Speaker . . . . . . . . . . . . . . . . . 8W-80-103 Right Fog Lamp (Built-Up-Export) . . . . . 8W-80-103 Right Fog Lamp (Except Built-Up-Export) . . . . . . . . . . . . . . . . . 8W-80-104 Right Front Door Ajar Switch (Base) . . . . 8W-80-104 Right Front Door Lock Motor/Ajar Switch (Except Base) . . . . . . . . . . . . . . 8W-80-104 Right Front Park/Turn Signal Lamp (Except Built-Up-Export) . . . . . . . . . . 8W-80-104 Right Front Wheel Speed Sensor . . . . . . 8W-80-104 Right Full Open Switch (Power Sliding Door) . . . . . . . . . . . . . . 8W-80-105 Right Headlamp (Except Built-Up-Export) . . . . . . . . . . . . . . . . . 8W-80-105 Right Headlamp Leveling Motor (Built-Up-Export) . . . . . . . . . . . . . . . . 8W-80-105 Right High Beam Lamp (Built-Up-Export) . . . . . . . . . . . . . . . . 8W-80-105 Right Instrument Panel Speaker . . . . . . 8W-80-105 Right Liftgate Flood Lamp . . . . . . . . . . . 8W-80-106 Right Low Beam Lamp (Built-Up-Export) . . . . . . . . . . . . . . . . 8W-80-106 Right Mid Reading Lamp (Premium/Luxury) . . . . . . . . . . . . . . . . 8W-80-106 Right Park Lamp (Built-Up-Export) . . . . 8W-80-106 Right Power Mirror . . . . . . . . . . . . . . . . . 8W-80-106 RS 8W-80 CONNECTOR PIN-OUTS Component Page Right Rear Lamp Assembly . . . . . . . . . . . 8W-80-107 Right Rear Pillar Speaker . . . . . . . . . . . . 8W-80-107 Right Rear Reading Lamp (Luxury) . . . . 8W-80-107 Right Rear Speaker . . . . . . . . . . . . . . . . . 8W-80-107 Right Rear Vent Motor . . . . . . . . . . . . . . 8W-80-107 Right Rear Wheel Speed Sensor . . . . . . . 8W-80-108 Right Remote Radio Switch . . . . . . . . . . . 8W-80-108 Right Repeater Lamp (Built-Up-Export) . . . . . . . . . . . . . . . . 8W-80-108 Right Seat Airbag . . . . . . . . . . . . . . . . . . 8W-80-108 Right Side Impact Airbag Control Module . . . . . . . . . . . . . . . . . . 8W-80-108 Right Sliding Door Control Module C1 (Power Sliding Door) . . . . . . . . . . . . . . 8W-80-109 Right Sliding Door Control Module C2 (Power Sliding Door) . . . . . . . . . . . . . . 8W-80-109 Right Sliding Door Latch Sensing Switch (Power Sliding Door) . . . . . . . . . . . . . . 8W-80-109 Right Sliding Door Lock Motor (Power Sliding Door) . . . . . . . . . . . . . . 8W-80-110 Right Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) . . . . . . . . . . . . . 8W-80-110 Right Sliding Door Motor (Power Sliding Door) . . . . . . . . . . . . . . 8W-80-110 Right Speed Control Switch . . . . . . . . . . 8W-80-110 Right Stop/Turn Signal Relay (Trailer Tow) . . . . . . . . . . . . . . . . . . . . 8W-80-110 8W - 80 - 5 Component Right Turn Signal Lamp (Built-Up-Export) . . . . . . . . . . . . . . . . . Right Visor/Vanity Lamp (Premium/Luxury) . . . . . . . . . . . . . . . . Sentry Key Immobilizer Module . . . . . . . Siren (United Kingdom) . . . . . . . . . . . . . . Solenoid/Pressure Switch Assy (EATX) . . Speed Control Servo (Gas) . . . . . . . . . . . . Thatcham Alarm Module C1 (United Kingdom) . . . . . . . . . . . . . . . . Thatcham Alarm Module C2 (United Kingdom) . . . . . . . . . . . . . . . . Throttle Position Sensor (Gas) . . . . . . . . . Torque Converter Clutch Solenoid (ATX) . . . . . . . . . . . . . . . . . . . . . . . . . . Traction Control Switch . . . . . . . . . . . . . . Trailer Tow Connector (Except Built-Up-Export) . . . . . . . . . . . Transmission Control Module (EATX) . . . Transmission Range Sensor (EATX) . . . . TXV Solenoid (ATC) . . . . . . . . . . . . . . . . Vehicle Speed Sensor (MTX/ATX) . . . . . . Washer Fluid Level Switch . . . . . . . . . . . Water In Fuel Sensor (Diesel) . . . . . . . . . Wiper Module . . . . . . . . . . . . . . . . . . . . . Page 8W-80-111 8W-80-111 8W-80-111 8W-80-111 8W-80-111 8W-80-112 8W-80-112 8W-80-112 8W-80-112 8W-80-113 8W-80-113 8W-80-113 8W-80-114 8W-80-115 8W-80-115 8W-80-115 8W-80-115 8W-80-116 8W-80-116 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS RS A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT 2 Z153 18BK/GY GROUND A/C PRESSURE SENSOR - GRAY 4 WAY CAV CIRCUIT FUNCTION 1 C918 20BK/LB (DIESEL) A/C PRESSURE SENSOR GROUND 1 K900 18DB/DG (GAS) SENSOR GROUND 2 F851 20LB/PK (DIESEL) SENSOR REFERENCE VOLTAGE B 2 F855 18PK/YL (GAS) 5 VOLT SUPPLY 3 C18 20LB/BR (DIESEL) A/C PRESSURE SENSOR SIGNAL 3 C18 18LB/BR (GAS) A/C PRESSURE SENSOR SIGNAL 4 - - A/C-HEATER CONTROL C1 (MTC) - BLACK/RED 20 WAY CAV CIRCUIT FUNCTION 1 Z24 18BK/OR GROUND 2 C121 20DB/DG SENSOR GROUND 3 C22 20LB/WT (3 ZONE HVAC) REAR TEMPERATURE FEEDBACK SIGNAL 4 - - 5 F850 20LB/PK (3 ZONE HVAC) 5 VOLT SUPPLY 6 C900 18LB/VT WIPER DE-ICER DRIVER 7 C32 20DB/TN RECIRCULATION DOOR DRIVER (A) 8 C54 20LB/YL (3 ZONE HVAC) REAR BLEND DOOR DRIVER 9 C34 20DB/LB COMMON DOOR DRIVER (B) 10 D25 20WT/VT PCI BUS 11 - - 12 C121 20DB/DG (3 ZONE HVAC) REAR TEMPERATURE RETURN 13 F504 20GY/PK IGNITION SWITCH OUTPUT (RUN) 14 E12 20OR/GY PANEL LAMPS DRIVER 15 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL 16 C33 20LB/BR PASSENGER BLEND DOOR DRIVER (A) 17 C61 20DB/LG DRIVER BLEND DOOR DRIVER (A) 18 C35 20LB/OR MODE DOOR DRIVER (A) 19 C53 20LB (3 ZONE HVAC) REAR MODE DOOR DRIVER 20 C154 20LB/OR (3 ZONE HVAC) REAR COMMON DOOR DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 A/C-HEATER CONTROL C2 (MTC) - BLACK/BLUE 10 WAY CAV CIRCUIT FUNCTION 1 - - 2 C75 12DB/GY BLOWER MOTOR HIGH DRIVER 3 C74 12DB/WT BLOWER MOTOR M3 DRIVER 4 Z134 12BK/OR GROUND 5 C71 16DB/BR BLOWER MOTOR LOW DRIVER 6 - - 7 - - 8 - - 9 C73 14DB/VT BLOWER MOTOR M2 DRIVER 10 C72 16DB/OR BLOWER MOTOR M1 DRIVER ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY CAV CIRCUIT FUNCTION 1 - - 2 - - 3 K4 20BK/LB LOW IDLE POSITION SWITCH GROUND 4 - - 5 K151 20WT LOW IDLE POSITION SWITCH SENSE 6 - - 7 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL 8 K167 20BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND 9 - - 10 F852 20VT/PK ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY ADJUSTABLE PEDALS MODULE (EXCEPT BUILT-UP-EXPORT) - DK. GRAY 8 WAY CAV CIRCUIT FUNCTION 1 A108 18LG/RD FUSED B(+) 2 D25 20WT/VT PCI BUS 3 - - 4 Z140 18BK/YL GROUND 5 A114 18GY/RD FUSED B(+) (I.O.D.) 6 - - 7 Q100 20OR/WT ADJUSTABLE PEDALS SWITCH SENSE 8 Q900 20OR/BK ADJUSTABLE PEDALS SWITCH GROUND ADJUSTABLE PEDALS SWITCH (EXCEPT BUILT-UP-EXPORT) - WHITE 2 WAY CAV CIRCUIT FUNCTION 1 Q100 20OR/WT ADJUSTABLE PEDALS SWITCH SENSE 2 Q900 20OR/BK ADJUSTABLE PEDALS SWITCH GROUND 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS RS AIRBAG CONTROL MODULE (ORC) - YELLOW/RED 23 WAY CAV CIRCUIT FUNCTION 1 R54 18LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 2 R56 18LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 3 R62 18LB/PK PASSENGER SQUIB 2 LINE 2 4 R64 18LB/WT PASSENGER SQUIB 2 LINE 1 5 R42 18LB/BR PASSENGER SQUIB 1 LINE 2 6 R44 18LB/OR PASSENGER SQUIB 1 LINE 1 7 R53 18LG/YL DRIVER SEAT BELT TENSIONER LINE 2 8 R55 18LG/DG DRIVER SEAT BELT TENSIONER LINE 1 9 R61 18LG/PK DRIVER SQUIB 2 LINE 1 10 R63 18LG/WT DRIVER SQUIB 2 LINE 2 11 R43 18LG/BR DRIVER SQUIB 1 LINE 1 12 R45 18LG/OR DRIVER SQUIB 1 LINE 2 13 - - 14 F201 18PK/OR FCM OUTPUT (ORC RUN-START DRIVER) 15 F100 18PK/VT FCM OUTPUT (ORC RUN ONLY DRIVER) 16 Z12 18BK/OR GROUND 17 R59 18LG/TN DRIVER SEAT BELT SWITCH LINE 1 18 R57 18LG/GY DRIVER SEAT BELT SWITCH LINE 2 19 R60 18DB/LB PASSENGER SEAT BELT SWITCH LINE 1 20 R58 18LB/GY PASSENGER SEAT BELT SWITCH LINE 2 21 D25 18WT/VT PCI BUS 22 - - 23 - - AMBIENT TEMP SENSOR (EXCEPT BASE) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G31 18VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL 2 G931 18VT/BR AMBIENT TEMPERATURE SENSOR RETURN ATC REMOTE SENSOR (ATC) - 4 WAY CAV CIRCUIT FUNCTION 1 F600 20LB/PK PROTECTED IGNITION 2 D40 20WT/LB KDB NO. 2 CLOCK 3 C905 20BR/LB SENSOR RETURN 4 D18 20WT/YL KDB NO. 2 DATA RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 AUTO TEMP CONTROL C1 - WHITE 13 WAY CAV CIRCUIT FUNCTION 1 C161 20LB/WT DRIVER BLEND DOOR DRIVER (B) 2 C61 20DB/LG DRIVER BLEND DOOR DRIVER (A) 3 C133 20DB/WT PASSENGER BLEND DOOR DRIVER (B) 4 C33 20LB/BR PASSENGER BLEND DOOR DRIVER (A) 5 C132 20DB/YL RECIRCULATION DOOR DRIVER (B) 6 C32 20DB/TN RECIRCULATION DOOR DRIVER (A) 7 C135 20DB/GY MODE DOOR DRIVER (B) 8 C35 20LB/OR MODE DOOR DRIVER (A) 9 C53 20LB REAR MODE DOOR DRIVER (A) 10 C154 20LB/OR REAR MODE DOOR DRIVER (B) 11 C54 20LB/YL REAR BLEND DOOR DRIVER (A) 12 C169 20DB/OR REAR BLEND DOOR DRIVER (B) 13 - - AUTO TEMP CONTROL C2 - BLACK 13 WAY CAV CIRCUIT FUNCTION 1 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL 2 C121 20DB/DG SENSOR GROUND 3 E12 20OR/GY PANEL LAMPS DRIVER 4 A114 20GY/RD FUSED B(+) (I.O.D.) 5 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 6 D25 20WT/VT PCI BUS 7 C56 20DB/LB BLOWER MOTOR CONTROL 8 C59 20DB/LB REAR BLOWER MOTOR CONTROL 9 D22 20WT/TN KDB CLOCK 10 D17 20WT/DG KDB DATA 11 Z24 18BK/OR GROUND 12 C200 20LB/DG TXV SOLENOID FEED 13 C900 18LB/VT WIPER DE-ICER DRIVER AUTO TEMP CONTROL C3 - 4 WAY CAV CIRCUIT FUNCTION 1 F600 20LB/PK PROTECTED IGNITION 2 D40 20WT/LB KDB NO. 2 CLOCK 3 C905 20BR/LB SENSOR RETURN 4 D18 20WT/YL KDB NO. 2 DATA AUTOMATIC DAY/NIGHT MIRROR (PREMIUM/LUXURY) - BLACK 7 WAY CAV CIRCUIT FUNCTION 1 F503 20BK/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 Z113 20BK GROUND 3 L1 20BK/WT BACK-UP LAMP FEED 4 P112 20BK/OR (EXCEPT BUILT-UP-EXPORT) MIRROR B(+) 5 P114 20BK/LB (EXCEPT BUILT-UP-EXPORT) MIRROR B(-) 6 - - 7 L24 20BK/GY (EXCEPT BUILT-UP-EXPORT) AUTOMATIC HEADLAMP SWITCH SENSOR 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS RS AUTOSTICK SWITCH (EXCEPT BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T55 20YL/VT AUTOSTICK/OVERDRIVE OFF MUX INPUT 2 Z65 20BK/YL GROUND BACK-UP LAMP SWITCH (MTX) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T2 18DG/WT TRS REVERSE SENSE 2 Z252 18BK/WT GROUND BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND BLOWER MOTOR RESISTOR C1 (MTC) - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 C75 12DB/GY BLOWER MOTOR HIGH DRIVER 2 C74 12DB/WT BLOWER MOTOR M3 DRIVER 3 C73 14DB/VT BLOWER MOTOR M2 DRIVER 4 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT 5 C72 16DB/OR BLOWER MOTOR M1 DRIVER 6 C71 16DB/BR BLOWER MOTOR LOW DRIVER BLOWER MOTOR RESISTOR C2 (MTC) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 C70 12DG REAR BLOWER HIGH SPEED 2 C7 12BK HIGH SPEED BLOWER MOTOR RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 BODY CONTROL MODULE C1 - BLACK/BLACK 6 WAY CAV CIRCUIT FUNCTION 1 A102 12WT/RD FUSED B(+) 2 A701 16BR/RD FUSED B(+) (HAZARD) 3 Z100 12BK/TN GROUND 4 - - 5 A101 12VT/RD FUSED B(+) 6 - - BODY CONTROL MODULE C2 - BLACK/GREEN 34 WAY CAV CIRCUIT FUNCTION 1 L61 18WT/LB (BUILT-UP-EXPORT) LEFT FRONT TURN SIGNAL DRIVER 1 L61 18WT/LG (EXCEPT BUILT-UP-EXPORT) LEFT FRONT TURN SIGNAL DRIVER 2 L63 18WT/DG LEFT REAR TURN SIGNAL DRIVER 3 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER 4 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER 5 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 6 G25 20VT/TN (HIGH LINE) LIFTGATE SWITCH MUX 7 A114 20GY/RD FUSED B(+) (I.O.D.) 8 - - 9 L1 18WT/LG BACK-UP LAMP DRIVER 10 P3 20TN/WT LEFT FRONT DOOR LOCK DRIVER 11 P2 20TN/GY RIGHT FRONT DOOR LOCK DRIVER 12 P38 20TN/DB RIGHT SLIDING DOOR LOCK DRIVER 13 - - 14 - - 15 Z15 18BK/TN GROUND 16 G920 20VT/YL (MEMORY) MEMORY SELECT SWITCH RETURN 17 G153 20VT/YL (POWER LIFTGATE) LIFTGATE MODULE WAKE UP SIGNAL 18 P32 20TN/VT LEFT SLIDING DOOR LOCK DRIVER 19 Z10 18BK/TN GROUND 20 P5 20TN/OR LEFT SLIDING DOOR UNLOCK DRIVER 21 P164 18LG/DB (BUILT-UP-EXPORT) PASSENGER FOLDING MIRROR RELAY INPUT 22 P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE 23 - - 24 G200 20VT/BR (MEMORY) MEMORY SELECT SWITCH MUX 25 M22 20YL/OR COURTESY LAMPS DRIVER 26 P4 20TN/BR RIGHT FRONT DOOR UNLOCK DRIVER 27 P34 20TN/LB RIGHT SLIDING DOOR UNLOCK DRIVER 28 P1 20TN/LG LEFT FRONT DOOR UNLOCK DRIVER 29 P159 20TN/DG (BUILT-UP-EXPORT) DRIVER FOLDING MIRROR FOLD DRIVER 30 P174 20TN/LB (BUILT-UP-EXPORT) RIGHT FOLDING MIRROR UNFOLD DRIVER 31 P171 20TN/YL (BUILT-UP-EXPORT) LEFT FOLDING MIRROR UNFOLD DRIVER 32 W13 18BR/LG REAR WIPER MOTOR CONTROL 33 M24 20YL/WT COURTESY LAMPS DRIVER 34 L38 20WT/YL (BUILT-UP-EXPORT) REAR FOG LAMP SWITCH OUTPUT 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS RS BODY CONTROL MODULE C3 - BLACK/WHITE 34 WAY CAV CIRCUIT 1 G23 20VT/DB (POWER SLIDING DOOR) SLIDING DOORS OVERHEAD SWITCH MUX FUNCTION 2 D23 20WT/BR FLASH PROGRAM ENABLE 3 G152 20VT/GY (POWER SLIDING DOOR) RIGHT SLIDING DOOR WAKE UP SIGNAL 4 G151 20VT/BR (POWER SLIDING DOOR) LEFT SLIDING DOOR WAKE UP SIGNAL 5 G76 20VT/YL RIGHT SLIDING DOOR AJAR SWITCH SENSE 6 G74 20VT/WT (RHD) RIGHT FRONT DOOR AJAR SWITCH SENSE 6 G75 20VT (LHD) LEFT FRONT DOOR AJAR SWITCH SENSE 7 G75 20VT (RHD) LEFT FRONT DOOR AJAR SWITCH SENSE 7 G74 20VT/WT (LHD) RIGHT FRONT DOOR AJAR SWITCH SENSE 8 G77 20VT/GY LEFT SLIDING DOOR AJAR SWITCH SENSE 9 E10 20OR/DG (ATC) (3 ZONE HVAC) PANEL LAMPS DRIVER (REAR BLOWER SWITCH) 10 - - 11 L162 20WT/VT (BUILT-UP-EXPORT) RIGHT SIDE REPEATER LAMP FEED 12 G42 20VT/YL (POWER SLIDING DOOR) (EXCEPT TOWN & COUNTRY) RIGHT SLIDING DOOR PILLAR SWITCH MUX 12 G42 20VT/WT (POWER SLIDING DOOR) RIGHT SLIDING DOOR PILLAR SWITCH MUX (TOWN & COUNTRY) 13 G165 20VT/GY LIFTGATE CYLINDER LOCK SWITCH MUX 14 G163 20VT/LB LEFT CYLINDER LOCK SWITCH MUX 15 G162 20VT/WT (EXCEPT BUILT-UP-EXPORT) RIGHT CYLINDER LOCK SWITCH MUX 15 G162 20VT/TN (BUILT-UP-EXPORT) RIGHT CYLINDER LOCK SWITCH MUX 16 - - 17 F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN) 18 G41 20VT/DG (POWER SLIDING DOOR) LEFT SLIDING DOOR PILLAR SWITCH MUX 19 L163 20WT/BR (BUILT-UP-EXPORT) LEFT SIDE REPEATER LAMP FEED 20 N4 18DB/WT FUEL LEVEL SENSOR SIGNAL 21 G161 20VT/DG (LHD) LEFT DOOR LOCK SWITCH MUX 21 G160 20VT/LG (RHD) RIGHT DOOR LOCK SWITCH MUX 22 G160 20VT/LG (LHD) RIGHT DOOR LOCK SWITCH MUX 22 G161 20VT/DG (RHD) LEFT DOOR LOCK SWITCH MUX 23 D25 20WT/VT PCI BUS 24 - - 25 M11 20YL/VT COURTESY LAMPS DRIVER 26 P31 20TN/YL (POWER RELEASE) (EXCEPT BUILT-UP-EXPORT LHD SWB GAS) LIFTGATE RELEASE DRIVER 26 P31 20TN/DG (POWER RELEASE) (BUILT-UP-EXPORT LHD SWB GAS) LIFTGATE RELEASE DRIVER 27 - - 28 - - 29 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE 30 G70 20VT/LB HOOD AJAR SWITCH SENSE 31 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT (RUN) 32 - - 33 M21 20YL/BR COURTESY LAMPS DRIVER 34 M27 20YL/LB READING LAMPS DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 BODY CONTROL MODULE C4 - BLACK/GRAY 34 WAY CAV CIRCUIT FUNCTION 1 E18 20OR/LB (POWER MIRRORS) PANEL LAMPS DRIVER (MIRROR SWITCH) 2 E12 20OR/GY PANEL LAMPS DRIVER (HVAC) 3 E19 20OR/BR PANEL LAMPS DRIVER (HEADLAMP SWITCH) 4 D9 20WT/GY RKE MODULE PROGRAM ENABLE 5 G150 20VT/BR INSTRUMENT CLUSTER WAKE UP SENSE 6 - - 7 P162 20LG/DG (BUILT-UP-EXPORT) PASSENGER FOLDING MIRROR RELAY CONTROL 8 G69 20VT/WT (VTSS) VTSS INDICATOR DRIVER 9 L161 20WT/LG LEFT TURN INDICATOR DRIVER 10 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 11 E14 20OR/TN PANEL LAMPS DRIVER (RADIO) 12 E13 20OR/YL PANEL LAMPS DRIVER (INSTRUMENT CLUSTER) 13 X920 20GY/OR RADIO CONTROL MUX RETURN 14 G900 20VT/OR IGNITION SWITCH SENSE RETURN 15 - - 16 - - 17 L160 20WT/TN RIGHT TURN INDICATOR DRIVER 18 M26 20YL/DB HALO LAMP DRIVER 19 - - 20 - - 21 - - 22 G902 20VT/OR MULTI-FUNCTION SWITCH MUX RETURN 23 - - 24 - - 25 - - 26 M28 20YL/TN GLOVE BOX LAMP DRIVER 27 - - 28 - - 29 - - 30 - - 31 G96 20VT/DG REMOTE KEYLESS ENTRY INTERFACE 32 B27 20DG/WT TRACTION CONTROL SWITCH SENSE 33 P136 20TN/YL (BUILT-UP-EXPORT) FOLDING MIRROR SWITCH SENSE 34 G26 20VT/OR CHIME DRIVER 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS RS BODY CONTROL MODULE C5 - BLACK/BLACK 34 WAY CAV CIRCUIT FUNCTION 1 L91 20WT/DB HAZARD SWITCH SENSE 2 - - 3 - - 4 - - 5 - - 6 - - 7 - - 8 - - 9 - - 10 G20 20VT/BR IGNITION SWITCH SENSE 11 - - 12 - - 13 - - 14 - - 15 - - 16 G926 20VT/WT REAR WIPER SWITCH MUX RETURN 17 L900 20WT/YL HEADLAMP SWITCH MUX RETURN 18 L307 20WT/BR HEADLAMP SWITCH MUX 19 - - 20 - - 21 - - 22 - - 23 - - 24 - - 25 L36 20WT/DB (BUILT-UP-EXPORT) REAR FOG LAMP INDICATOR DRIVER 26 X20 20GY/WT RADIO CONTROL MUX 27 G194 20VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX 28 W26 20BR/DB REAR WIPER SWITCH MUX 29 W52 20BR/YL FRONT WIPER SWITCH MUX 30 E2 20OR/BR PANEL LAMPS DIMMER SIGNAL 31 L305 20WT/LB TURN SIGNAL SWITCH MUX 32 - - 33 - - 34 L39 20WT/OR (HIGH LINE) FRONT FOG LAMP INDICATOR DRIVER BOOST PRESSURE SENSOR (DIESEL) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K121 20DB BOOST PRESSURE SENSOR GROUND 2 K21 20DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 F851 18LB/PK SENSOR REFERENCE VOLTAGE B 4 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL BRAKE FLUID LEVEL SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION A B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE B Z420 20BK/OR GROUND RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 BRAKE LAMP SWITCH - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 A103 18GY/RD FUSED B(+) 2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3 V30 20VT/WT (GAS) SPEED CONTROL BRAKE SWITCH OUTPUT 4 V32 20VT/YL (GAS) SPEED CONTROL ON/OFF SWITCH SENSE 5 Z429 20BK/OR GROUND 6 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID (EATX) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL 2 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START) C100 - BLACK (BODY SIDE) CAV CIRCUIT 1 D21 20WT/DG (BUILT-UP-EXPORT) 1 D21 20WT/BR (EXCEPT BUILT-UP-EXPORT) 2 D16 20WT/OR 3 K119 20DB/LG (DIESEL) 3 D20 20WT/LG (GAS) 4 D25 20WT/VT 5 Z111 18BK/WT (EXCEPT BUILT-UP-EXPORT) 5 Z111 20BK/WT (BUILT-UP-EXPORT) 6 N1 16DB/OR (DIESEL) 7 N2 18DB/YL (DIESEL) 8 K22 20OR/DB (DIESEL) 8 V32 20VT/YL (GAS) 9 B29 20DG/WT 10 V37 20VT 11 K167 20BR/YL (DIESEL) 11 V30 20VT/WT (GAS) 12 K900 20DB/DG 13 B1 18DG/OR (ANTILOCK BRAKES) 14 B2 18DG/LB (ANTILOCK BRAKES) 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C100 - BLACK (POWERTRAIN SIDE) CAV CIRCUIT 1 D21 18WT/BR 2 D16 18WT/OR (EATX) 3 K119 20DB/LG (DIESEL) 3 D20 18WT/LG (GAS) 4 D25 20WT/VT (DIESEL) 4 D25 18WT/VT (GAS) 5 Z111 18BK/WT 6 N1 18DB/OR (DIESEL) 7 N2 18DB/YL (DIESEL) 8 K22 20OR/DB (DIESEL) 8 V32 18VT/YL (GAS) 9 B29 18DG/WT (GAS) 9 B29 20DG/WT (DIESEL) 10 V37 18VT (GAS) 10 V37 20VT/TN (DIESEL) 11 K167 20BR/YL (DIESEL) 11 V30 18VT/WT (GAS) 12 K900 18DB/DG 13 B1 18DG/OR (ANTILOCK BRAKES) 14 B2 18DG/LB (ANTILOCK BRAKES) C101 - LT. GRAY (BODY SIDE) CAV CIRCUIT 1 L50 18WT/TN 2 - 3 F853 20LG/PK (DIESEL) 4 K900 18DB/DG (DIESEL) 5 B4 18DG/GY (ANTILOCK BRAKES) 6 B3 18DG/YL (ANTILOCK BRAKES) 7 F500 18DG/PK 8 K4 20BK/LB (DIESEL) 9 T55 18YL/VT (AUTOSTICK) 9 F852 20VT/PK (DIESEL) 10 K151 20WT (DIESEL) C101 - LT. GRAY (POWERTRAIN SIDE) CAV CIRCUIT 1 L50 20WT/TN (DIESEL) 1 L50 18WT/TN (GAS) (ANTILOCK BRAKES) 2 - 3 F853 20LG/PK (DIESEL) 4 - 5 B4 18DG/GY (ANTILOCK BRAKES) 6 B3 18DG/YL (ANTILOCK BRAKES) 7 F500 18DG/PK 8 K4 20BK/LB (DIESEL) 9 K853 20DB/BR (DIESEL) 9 T55 18YL/VT (EATX) 10 K151 20WT (DIESEL) RS RS 8W-80 CONNECTOR PIN-OUTS C102 (2.4L) - BLACK (FUEL RAIL SIDE) CAV CIRCUIT 1 K11 16BR/YL 2 K12 16BR/DB 3 K13 16BR/LB 4 K14 16BR/TN 5 K342 16BR/WT 6 K900 18DB/DG 7 K2 18VT/OR 8 K1 18VT/BR 9 - 10 F855 18OR/PK (EXCEPT BUILT-UP-EXPORT) 10 F855 18PK/YL (BUILT-UP-EXPORT) C102 (2.4L) - BLACK (POWERTRAIN SIDE) CAV CIRCUIT 1 K11 16BR/YL 2 K12 16BR/DB 3 K13 16BR/LB 4 K14 16BR/TN 5 K342 16BR/WT 6 K900 18DB/DG 7 K2 18VT/OR 8 K1 18VT/BR 9 - 10 F855 18PK/YL C102 (3.3L/3.8L) - BLACK (FUEL RAIL SIDE) CAV CIRCUIT 1 K342 16BR/WT 2 K1 18VT/BR 3 K11 16BR/YL 4 K12 16BR/DB 5 K13 16BR/LB 6 K14 16BR/TN 7 K900 18DB/DG 8 K38 16BR/OR 9 K58 16BR/VT 10 F855 18OR/PK (EXCEPT BUILT-UP-EXPORT) 10 F855 18PK/YL (BUILT-UP-EXPORT) 8W - 80 - 17 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C102 (3.3L/3.8L) - BLACK (POWERTRAIN SIDE) CAV CIRCUIT 1 K342 16BR/WT 2 K1 18VT/BR 3 K11 16BR/YL 4 K12 16BR/DB 5 K13 16BR/LB 6 K14 16BR/TN 7 K900 18DB/DG 8 K38 16BR/OR 9 K58 16BR/VT 10 F855 18PK/YL C103 (DIESEL) - BLACK (POWERTRAIN SIDE) CAV CIRCUIT 1 K342 16BR/WT 2 K342 16BR/WT 3 N122 20DB/YL 4 N210 20DB/DG 5 A201 12RD/LG 6 - C103 (DIESEL) - BLACK (FRONT END LIGHTING SIDE) CAV CIRCUIT 1 K342 16BR/WT 2 K342 16BR/WT 3 N122 20DB/YL 4 N210 18DB/DG 5 A201 12RD/LG 6 - C106 (BUILT-UP-EXPORT) - BLACK (FRONT END LIGHTING SIDE) CAV CIRCUIT 1 L43 18WT/DB 2 L33 18WT/LG 3 L77 18WT/BR 4 L61 16WT/LG 5 Z343 18BK/LG 6 L13 20WT/YL 7 Z203 20BK/YL 8 Z377 18BK/BR RS RS 8W-80 CONNECTOR PIN-OUTS C106 (BUILT-UP-EXPORT) - BLACK/YELLOW (COMPONENT SIDE) CAV CIRCUIT 1 L43 16WT 2 L33 16GY 3 L77 16BK 4 L61 16YL 5 Z343 16BR 6 L13 16RD 7 Z203 16BR 8 - C107 (BUILT-UP-EXPORT) - BLACK (FRONT END LIGHTING SIDE) CAV CIRCUIT 1 L44 16WT/TN 2 L34 16WT/GY 3 L78 18WT/OR 4 L60 16WT/TN 5 Z344 16BK/TN 6 L13 20WT/YL 7 Z203 20BK/YL 8 Z378 18BK/TN (DIESEL) 8 Z378 18BK/LB (GAS) C107 (BUILT-UP-EXPORT) - BLACK/YELLOW (COMPONENT SIDE) CAV CIRCUIT 1 L44 16WT 2 L34 16GY 3 L78 16BK 4 L60 16YL 5 Z344 16BR 6 L13 16RD 7 Z203 16BR 8 - 8W - 80 - 19 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C200 - GRAY (BODY SIDE) CAV CIRCUIT 1 C151 18LB/DG (3 ZONE HVAC) 1 C200 20LB/DG (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 2 A106 20LB/RD 3 A108 18LG/RD 4 C152 16LB/LG (3 ZONE HVAC) 4 C59 20DB/LB (AUTOMATIC TEMPERATURE CONTROL) 5 P159 20TN/DG (BUILT-UP-EXPORT) 5 C200 20LB/DG (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 6 K32 18DB/YL (GAS) 7 C53 20LB (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) 8 C16 18DB/GY (BUILT-UP-EXPORT) 8 C16 20DB/GY (EXCEPT BUILT-UP-EXPORT) 9 D17 20WT/DG (AUTOMATIC TEMPERATURE CONTROL) 9 C22 20LB/WT (3 ZONE HVAC) 10 L13 20WT/YL (BUILT-UP-EXPORT) 10 C50 12DB/OR (3 ZONE HVAC) 11 C7 12DB 12 Z135 12BK/LB (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 12 D22 20WT/TN (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 12 C153 12DB/BR (3 ZONE HVAC) 13 Z849 12BK/OR 14 A105 16DB/RD (BUILT-UP-EXPORT) 14 A105 18DB/RD (EXCEPT BUILT-UP-EXPORT) 15 A114 16GY/RD 16 F306 16DB/PK 17 C154 20LB/OR (3 ZONE HVAC) 17 C169 20DB/OR (AUTOMATIC TEMPERATURE CONTROL) 18 C121 20DB/DG (3 ZONE HVAC) 18 D22 20WT/TN (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 18 P171 20TN/YL (BUILT-UP-EXPORT) 19 P160 18TN/LG (BUILT-UP-EXPORT) 20 F302 18GY/PK 21 F2 18PK/WT (GAS) 22 L78 18WT/OR (BUILT-UP-EXPORT) 22 Q900 20OR/BK (EXCEPT BUILT-UP-EXPORT) 23 P174 20TN/LB (BUILT-UP-EXPORT) 23 Q100 20OR/WT (EXCEPT BUILT-UP-EXPORT) 24 D25 20WT/VT 25 D25 20WT/VT 26 D25 20WT/VT 27 D25 20WT/VT 28 D25 20WT/VT 29 F20 20PK/WT 30 F100 18PK/VT 31 F201 18PK/OR 32 F850 20LB/PK (3 ZONE HVAC) 32 F504 20GY/PK (AUTOMATIC TEMPERATURE CONTROL) 33 P7 20LG/DG 34 P8 20LG/WT 35 P64 20TN (MEMORY) 36 P65 20TN/VT (MEMORY) RS RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C200 - GRAY (BODY SIDE) CAV CIRCUIT 37 P66 20TN/LG (MEMORY) 38 P67 20TN/OR (MEMORY) 39 P68 20TN/YL (MEMORY) 40 P69 20TN/WT (EXCEPT BUILT-UP-EXPORT) (MEMORY) 40 P69 20TN/DB (BUILT-UP-EXPORT) (MEMORY) 41 P70 18TN/LB (MEMORY) 42 P71 18TN/GY (BUILT-UP-EXPORT) (MEMORY) 42 P71 18TN/DG (EXCEPT BUILT-UP-EXPORT) (MEMORY) 43 P72 18TN/GY (MEMORY) 44 P73 18TN/VT (EXCEPT BUILT-UP-EXPORT) (MEMORY) 44 P73 18TN/YL (BUILT UP-EXPORT) (MEMORY) 45 P74 18TN/YL (MEMORY) 46 P75 18TN/DB (BUILT-UP-EXPORT) (MEMORY) 46 P75 18TN/LG (EXCEPT BUILT-UP-EXPORT) (MEMORY) 47 P112 20TN/OR (EXCEPT BUILT-UP-EXPORT/POWER MIRRORS/EXCEPT TOWN & COUNTRY) 47 P112 20BK/OR (EXCEPT BUILT-UP-EXPORT/POWER MIRRORS/TOWN & COUNTRY) 47 D23 20WT/BR (RHD) 48 P114 20TN/WT (EXCEPT BUILT-UP-EXPORT) (POWER MIRRORS) 48 B25 20DG/WT (BUILT-UP-EXPORT) 49 C154 20LB/OR (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) 50 Z104 18BK/LG 51 X156 20GY/LB (PREMIUM 8 SPEAKER) 52 X154 20GY/YL (PREMIUM 8 SPEAKER) 53 R57 18LG/GY 54 R58 18LB/GY 55 R59 18LG/TN 56 R60 18LB/TN 57 T55 20YL/VT (AUTOSTICK) 57 P162 18LG/DG (BUILT-UP-EXPORT) 58 T751 20YL 59 X15 16GY/DG (PREMIUM 8 SPEAKER) 60 V37 20VT 61 X3 20DG/VT 62 C54 20LB/YL (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) 63 A701 16BR/RD 64 X51 20DG/DB 65 X52 20GY/DB 66 X53 20DG 67 X54 20GY 68 X55 20DG/BR 69 X56 20GY/BR 70 X57 20DG/OR 71 X58 20GY/OR 72 X153 20DG/YL (PREMIUM 8 SPEAKER) 73 K900 20DB/DG 74 X155 20DG/LB (PREMIUM 8 SPEAKER) 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C200 - GRAY (INSTRUMENT PANEL SIDE) CAV CIRCUIT 1 C200 20LB/DG (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 1 C151 18LB/DG (3 ZONE HVAC) 2 A106 20LB/RD 3 A108 18LG/RD 4 C59 20DB/LB (AUTOMATIC TEMPERATURE CONTROL) 4 C152 16LB/LG (3 ZONE HVAC) 5 P159 20TN/DG (BUILT-UP-EXPORT) 5 C200 20LB/DG (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 6 K32 18DB/YL 7 C53 20LB (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) 8 C16 20DB/GY (POWER MIRRORS) 9 C22 20LB/WT (3 ZONE HVAC) 9 D17 20WT/DG (AUTOMATIC TEMPERATURE CONTROL) 10 L13 20WT/YL (BUILT-UP-EXPORT) 10 C50 12DB/OR (3 ZONE HVAC) 11 C7 12DB 12 C153 12DB/BR (3 ZONE HVAC) 12 D22 20WT/TN (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 12 Z135 12BK/LB (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 13 Z849 12BK/OR 14 A105 16DB/RD 15 A114 16GY/RD 16 F306 16DB/PK 17 C169 20DB/OR (AUTOMATIC TEMPERATURE CONTROL) 17 C154 20LB/OR (3 ZONE HVAC) 18 C121 20DB/DG (3 ZONE HVAC) 18 D22 20WT/TN (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) 18 P171 20TN/YL (BUILT-UP-EXPORT) 19 P160 18TN/LG (BUILT-UP-EXPORT) 20 F302 18GY/PK 21 F2 18PK/YL 22 Q900 20OR/BK (EXCEPT BUILT-UP-EXPORT) 22 L78 20WT/OR (BUILT-UP-EXPORT) 23 Q100 20OR/WT (EXCEPT BUILT-UP-EXPORT) 23 P174 20TN/LB (BUILT-UP-EXPORT) 24 D25 18WT/VT 25 D25 18WT/VT (EXCEPT BUILT-UP-EXPORT) 25 D25 20WT/VT (BUILT-UP-EXPORT) 26 D25 20WT/VT 27 D25 20WT/VT 28 D25 20WT/VT 29 F20 20PK/WT 30 F100 18PK/VT 31 F201 18PK/OR 32 F504 20GY/PK (AUTOMATIC TEMPERATURE CONTROL) 32 F850 20LB/PK (3 ZONE HVAC) 33 P7 20LG/DG 34 P8 20LG/WT 35 P64 20TN (MEMORY) 36 P65 20TN/VT (MEMORY) 37 P66 20TN/LG (MEMORY) 38 P67 20TN/OR (MEMORY) 39 P68 20TN/YL (MEMORY) RS RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C200 - GRAY (INSTRUMENT PANEL SIDE) CAV CIRCUIT 40 P69 20TN/WT (MEMORY) 41 P70 18TN/LB (MEMORY) 42 P71 18TN/DG (MEMORY) 43 P72 18TN/GY (MEMORY) 44 P73 18TN/VT (MEMORY) 45 P74 18TN/DB (MEMORY) 46 P75 18TN/LG (MEMORY) 47 D23 20WT/BR (RHD) 47 P112 20TN/OR (EXCEPT BUILT-UP-EXPORT) (MEMORY POWER MIRRORS) 48 B25 20DG/WT (BUILT-UP-EXPORT) 48 P114 20TN/WT (EXCEPT BUILT-UP-EXPORT) (MEMORY POWER MIRRORS) 49 C154 20LB/OR (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) 50 Z104 18BK/LG 51 X156 20GY/LB (PREMIUM 8 SPEAKER) 52 X154 20GY/YL (PREMIUM 8 SPEAKER) 53 R57 18LG/GY 54 R58 18LB/GY 55 R59 18LG/TN 56 R60 18DB/LB 57 T55 20YL/VT (AUTOSTICK) 57 P162 20LG/DG (BUILT-UP-EXPORT) 58 T751 20YL 59 X15 16GY/DG (PREMIUM 8 SPEAKER) 60 V37 20VT 61 X3 20DG/VT 62 C54 20LB/YL (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) 63 A701 16BR/RD 64 X51 20DG/DB 65 X52 20GY/DB 66 X53 20DG 67 X54 20GY 68 X55 20DG/BR 69 X56 20GY/BR 70 X57 20DG/OR 71 X58 20GY/OR 72 X153 20DG/YL (PREMIUM 8 SPEAKER) 73 K900 20DB/DG 74 X155 20DG/LB (PREMIUM 8 SPEAKER) C201 - YELLOW (INSTRUMENT PANEL SIDE) CAV CIRCUIT 1 R53 18LG/YL 2 R55 18LG/DG 3 R54 18LB/YL 4 R56 18LB/DG 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C201 - YELLOW (BODY SIDE) CAV CIRCUIT 1 R53 18LG/YL 2 R55 18LG/DG 3 R54 18LB/YL 4 R56 18LB/DG C202 - GRAY (INSTRUMENT PANEL SIDE) CAV CIRCUIT 1 Z134 12BK/OR (AUTOMATIC TEMPERATURE CONTROL) 2 C34 20DB/LB (MANUAL TEMPERATURE CONTROL) 2 C56 20DB/LB (AUTOMATIC TEMPERATURE CONTROL) 3 C32 20DB/TN 4 C33 20LB/BR 5 C61 20DB/LG 6 C35 20LB/OR 7 C7 12DB (AUTOMATIC TEMPERATURE CONTROL) 8 C132 20DB/YL (AUTOMATIC TEMPERATURE CONTROL) 9 C133 20DB/WT (AUTOMATIC TEMPERATURE CONTROL) 10 C161 20LB/WT (AUTOMATIC TEMPERATURE CONTROL) 11 C135 20DB/GY (AUTOMATIC TEMPERATURE CONTROL) 12 C21 20DB/LG 13 C121 20DB/DG C202 - GRAY (COMPONENT SIDE) CAV CIRCUIT 1 Z134 12BK/OR (AUTOMATIC TEMPERATURE CONTROL) 2 C34 20DB/LB (MANUAL TEMPERATURE CONTROL) 2 C56 20DB/LB (AUTOMATIC TEMPERATURE CONTROL) 3 C32 20DB/TN 4 C33 20LB/BR 5 C61 20LB/WT (MANUAL TEMPERATURE CONTROL) 5 C61 20DB/LG (AUTOMATIC TEMPERATURE CONTROL) 6 C35 20LB/OR 7 C7 12DB (AUTOMATIC TEMPERATURE CONTROL) 8 C132 20DB/YL (AUTOMATIC TEMPERATURE CONTROL) 9 C133 20DB/WT (AUTOMATIC TEMPERATURE CONTROL) 10 C161 20LB/WT (AUTOMATIC TEMPERATURE CONTROL) 11 C135 20DB/GY (AUTOMATIC TEMPERATURE CONTROL) 12 C21 20DB/LG 13 C121 20DB/DG C203 (UNITED KINGDOM) - WHITE (BODY SIDE) CAV CIRCUIT 1 D97 18WT/OR 2 D96 18WT/LB 3 A600 18RD/LB 4 G944 18LB/BR RS RS 8W-80 CONNECTOR PIN-OUTS C203 (UNITED KINGDOM) - WHITE (INSTRUMENT PANEL SIDE) CAV CIRCUIT 1 D97 20WT/OR 2 D96 20WT/LB 3 A600 20RD/LB 4 G944 20LB/BR C300 (LHD) - BLACK (LEFT DOOR SIDE) CAV CIRCUIT 1 G75 20VT 2 Z75 20BK/VT (EXCEPT POWER LOCKS) 2 Z821 12BK/BR (POWER LOCKS) 3 X53 20DG 4 X55 20DG/BR 5 G161 20VT/DG (POWER LOCKS) 6 P1 20TN/LG (POWER LOCKS) 7 P3 20TN/WT (POWER LOCKS) 8 F304 12WT/PK (POWER WINDOWS) 8 F304 16WT/PK (EXCEPT POWER WINDOWS) 9 - 10 - 11 Q13 16OR/DB (POWER WINDOWS) 12 Q23 16OR/LB (POWER WINDOWS) 13 Q14 16OR/GY (POWER WINDOWS) 14 Q24 16OR/DG (POWER WINDOWS) C300 (LHD) - BLACK (BODY SIDE) CAV CIRCUIT 1 G75 20VT 2 Z821 12BK/BR 3 X53 20DG 4 X55 20DG/BR 5 G161 20VT/DG 6 P1 20TN/LG 7 P3 20TN/WT 8 F304 12WT/PK (POWER WINDOWS) 8 F302 18GY/PK (EXCEPT POWER WINDOWS) 9 - 10 - 11 Q13 16OR/DB (POWER WINDOWS) 12 Q23 16OR/LB (POWER WINDOWS) 13 Q14 16OR/BR (POWER WINDOWS) (BUILT-UP-EXPORT) 13 Q14 16OR/GY (POWER WINDOWS) (EXCEPT BUILT-UP-EXPORT) 14 Q24 16OR/DG (POWER WINDOWS) 8W - 80 - 25 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C300 (RHD) - BLACK (LEFT DOOR SIDE) CAV CIRCUIT 1 G75 20VT 2 Z822 20BK/BR 3 X53 20DG 4 X55 20DG/BR 5 G161 20VT/DG 6 P1 20TN/LG 7 P3 20TN/WT 8 F304 12WT/PK 9 - 10 - C300 (RHD) - BLACK (BODY SIDE) CAV CIRCUIT 1 G75 20VT 2 Z822 20BK/BR 3 X53 20DG 4 X55 20DG/BR 5 G161 20VT/DG 6 P1 20TN/LG 7 P3 20TN/WT 8 F304 12WT/PK 9 - 10 - C301 - LT. GRAY (LEFT DOOR SIDE) CAV CIRCUIT 1 M21 20YL/BR 2 X13 16DG/GY 3 X15 16GY/DG 4 X153 20DG/YL 5 X155 20DG/LB 6 G163 20VT/LB (POWER LOCKS) 7 G200 20VT/BR (MEMORY) 8 G920 20VT/YL (MEMORY) 9 Q16 12OR/TN 10 Q26 12OR/GY C301 - LT. GRAY (BODY SIDE) CAV CIRCUIT 1 M21 20YL/BR 2 X13 16DG/GY 3 X15 16GY/DG 4 X153 20DG/YL 5 X155 20DG/LB 6 G163 20VT/LB (POWER LOCKS) 7 G200 20VT/BR (LHD/MEMORY) 8 G920 20VT/YL (LHD/MEMORY) 9 Q16 12OR/TN 10 Q26 12OR/GY RS RS 8W-80 CONNECTOR PIN-OUTS C302 - LT. GRAY (RIGHT DOOR SIDE) CAV CIRCUIT 1 M21 20YL/BR 2 X13 16DG/GY 3 X15 16GY/DG 4 X154 20GY/YL 5 X156 20GY/LB 6 G162 20VT/WT (POWER LOCKS) 7 G200 20VT/BR (RHD) (MEMORY) 8 G920 20VT/YL (RHD) (MEMORY) 9 Q16 12OR/TN 10 Q26 12OR/GY C302 - LT. GRAY (BODY SIDE) CAV CIRCUIT 1 M21 20YL/BR 2 X13 16DG/GY 3 X15 16GY/DG 4 X154 20GY/YL 5 X156 20GY/LB 6 G162 20VT/TN (POWER LOCKS) (BUILT-UP-EXPORT) 6 G162 20VT/WT (POWER LOCKS) (EXCEPT BUILT-UP-EXPORT) 7 G200 20VT/BR (RHD) (MEMORY) 8 G920 20VT/YL (RHD) (MEMORY) 9 Q16 12OR/TN 10 Q26 12OR/GY C303 (LHD) - BLACK (RIGHT DOOR SIDE) CAV CIRCUIT 1 G74 20VT/WT 2 Z74 20BK/WT (BASE) 2 Z822 20BK/BR (EXCEPT BASE) 3 X54 20GY 4 X56 20GY/BR 5 G160 20VT/LG (POWER LOCKS) 6 P2 20TN/GY (POWER LOCKS) 7 P4 20TN/BR (POWER LOCKS) 8 F304 16WT/PK (EXCEPT POWER WINDOWS) 8 F304 12WT/PK (POWER WINDOWS) 9 - 10 - 8W - 80 - 27 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C303 (LHD) - BLACK (BODY SIDE) CAV CIRCUIT 1 G74 20VT/WT 2 Z822 20BK/BR 3 X54 20GY 4 X56 20GY/BR 5 G160 20VT/LG 6 P2 20TN/GY 7 P4 20TN/BR 8 F304 18GY/PK (EXCEPT POWER WINDOWS) 8 F304 12WT/PK (POWER WINDOWS) 9 - 10 - C303 (RHD) - BLACK (RIGHT DOOR SIDE) CAV CIRCUIT 1 G74 20VT/WT 2 Z821 12BK/BR 3 X54 20GY 4 X56 20GY/BR 5 G160 20VT/LG 6 P2 20TN/GY 7 P4 20TN/BR 8 F304 12WT/PK 9 - 10 - 11 Q13 16OR/DB 12 Q23 16OR/LB 13 Q14 16OR/GY 14 Q24 16OR/DG C303 (RHD) - BLACK (BODY SIDE) CAV CIRCUIT 1 G74 20VT/WT 2 Z821 12BK/BR 3 X54 20GY 4 X56 20GY/BR 5 G160 20VT/LG 6 P2 20TN/GY 7 P4 20TN/BR 8 F304 12WT/PK 9 - 10 - 11 Q13 16OR/DB 12 Q23 16OR/LB 13 Q14 16OR/BR 14 Q24 16OR/DG RS RS 8W-80 CONNECTOR PIN-OUTS C304 - YELLOW (BODY SIDE) CAV CIRCUIT 1 R54 18LB/YL (RHD) 1 R53 18LG/YL (LHD) 2 R56 18LB/DG (RHD) 2 R55 18LG/DG (LHD) 3 R31 18LG/OR 4 R33 18LG/WT C304 - YELLOW (SEAT SIDE) CAV CIRCUIT 1 R54 18LB/YL (RHD) 1 R53 18LG/YL (LHD) 2 R56 18LB/DG (RHD) 2 R55 18LG/DG (LHD) 3 R31 18LG/OR 4 R33 18LG/WT C305 - GRAY (BODY SIDE) CAV CIRCUIT 1 Z849 12BK/OR 2 R57 18LG/GY 3 R59 18LG/TN 4 P7 20LG/DG 5 A210 14OR/RD 6 F503 20WT/PK 7 A110 12OR/RD 8 - 9 - 10 - 11 - 12 - 13 - C305 - GRAY (SEAT SIDE) CAV CIRCUIT 1 Z849 12BK/OR (HEATED SEAT) 1 Z849 14BK/OR (EXCEPT HEATED SEAT) 2 R57 18LG/GY 3 R59 18LG/TN 4 P7 20LG/DG (HEATED SEAT) 5 A210 14OR/RD (POWER/HEATED SEAT) 6 F503 20WT/PK (HEATED SEAT) 7 A110 12OR/RD (POWER/HEATED SEAT) 8 - 9 - 10 - 11 - 12 - 13 - 8W - 80 - 29 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C306 - YELLOW (BODY SIDE) CAV CIRCUIT 1 R53 18LG/YL (RHD) 1 R54 18LB/YL (LHD) 2 R55 18LG/DG (RHD) 2 R56 18LB/DG (LHD) 3 R32 18LB/OR 4 R34 18LB/WT C306 - YELLOW (SEAT SIDE) CAV CIRCUIT 1 R53 18LG/YL (RHD) 1 R54 18LB/YL (LHD) 2 R55 18LG/DG (RHD) 2 R56 18LB/DG (LHD) 3 R32 18LB/OR 4 R34 18LB/WT C307 - GRAY (BODY SIDE) CAV CIRCUIT 1 Z848 12BK/OR 2 R58 18LB/GY 3 R60 18LB/TN 4 P8 20LG/WT 5 A210 14OR/RD 6 F503 20WT/PK 7 - 8 - 9 - 10 - 11 - 12 - C307 - GRAY (SEAT SIDE) CAV CIRCUIT 1 Z848 18BK/OR (POWER/HEATED SEAT) 2 R58 18LB/GY 3 R60 18LB/TN 4 P8 20LG/WT (HEATED SEAT) 5 A210 14OR/RD (POWER/HEATED SEAT) 6 F503 20WT/PK (HEATED SEAT) 7 - 8 - 9 - 10 - 11 - 12 - RS RS 8W-80 CONNECTOR PIN-OUTS C308 - BLUE (LEFT DOOR WIRE TRACK ASSEMBLY SIDE) CAV CIRCUIT 1 Z77 20BK (MANUAL SLIDING DOOR) 1 Z825 14BK (POWER SLIDING DOOR) 2 P32 20BK/TN 3 G77 20BK/DG 4 P5 20BK/DB 5 - 6 - 7 G151 20BK/GY (POWER SLIDING DOOR) 8 D25 20BK/VT (POWER SLIDING DOOR) 9 - 10 A113 14BK/RD (POWER SLIDING DOOR) C308 - BLUE (BODY SIDE) CAV CIRCUIT 1 Z77 20BK/GY (EXCEPT BUILT-UP-EXPORT MANUAL SLIDING DOOR) 1 Z825 14BK/WT (BUILT-UP-EXPORT MANUAL SLIDING DOOR) (POWER SLIDING DOOR) 2 P32 20TN/VT 3 G77 20VT/GY 4 P5 20TN/OR 5 - 6 - 7 G151 20VT/BR (POWER SLIDING DOOR) 8 D25 20WT/VT (POWER SLIDING DOOR) 9 - 10 A113 12WT/RD (POWER SLIDING DOOR) C309 - GREEN (RIGHT DOOR WIRE TRACK ASSEMBLY SIDE) CAV CIRCUIT 1 Z76 20BK (MANUAL SLIDING DOOR) 1 Z824 14BK (POWER SLIDING DOOR) 2 P34 20BK/TN 3 G76 20BK/DG 4 P38 20BK/DB 5 - 6 - 7 G152 20BK/GY (POWER SLIDING DOOR) 8 D25 20BK/VT (POWER SLIDING DOOR) 9 - 10 A113 14BK/RD (POWER SLIDING DOOR) 8W - 80 - 31 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C309 - GREEN (BODY SIDE) CAV CIRCUIT 1 Z76 20BK/YL (EXCEPT BUILT-UP-EXPORT MANUAL SLIDING DOOR) 1 Z824 14BK/WT (EXCEPT BUILT-UP-EXPORT / POWER SLIDING DOORS) (BUILT-UP-EXPORT) 2 P34 20TN/LB 3 G76 20VT/YL 4 P38 20TN/DB 5 - 6 - 7 G152 20VT/GY (POWER SLIDING DOOR) 8 D25 20WT/VT (POWER SLIDING DOOR) 9 - 10 A113 12WT/RD (POWER SLIDING DOOR) C310 (FRONT CONSOLE) - BLACK (BODY SIDE) CAV CIRCUIT 1 Z746 16BK/DB 2 M27 20YL/LB 3 A105 18DB/RD C310 (FRONT CONSOLE) - BLACK (FRONT CONSOLE SIDE) CAV CIRCUIT 1 Z746 16BK 1 Z746 16BK 2 M27 18OR 3 A105 16RD C311 - GRAY (REAR A/C JUMPER SIDE) CAV CIRCUIT 1 C153 12 DB/BR (3 ZONE HVAC) 2 F850 20LB/PK (3 ZONE HVAC) 2 F504 20GY/PK (AUTOMATIC TEMPERATURE CONTROL) 3 C121 20DB/DG (3 ZONE HVAC) 3 D22 20WT/TN (AUTOMATIC TEMPERATURE CONTROL) 4 C22 20LB/DB (3 ZONE HVAC) 4 D17 20WT/DG (AUTOMATIC TEMPERATURE CONTROL) 5 C151 18LB/DG (3 ZONE HVAC) 6 - 7 C152 16LB/LG (3 ZONE HVAC) 8 E10 20OR/DG 9 Z409 20BK/OR (3 ZONE HVAC) 9 Z27 18BK/DG (AUTOMATIC TEMPERATURE CONTROL) 10 C50 12DB/OR (3 ZONE HVAC) RS RS 8W-80 CONNECTOR PIN-OUTS C311 - GRAY (BODY SIDE) CAV CIRCUIT 1 C153 12DB/BR (3 ZONE HVAC) 2 F850 20LB/PK (3 ZONE HVAC) 2 F504 20GY/PK (AUTOMATIC TEMPERATURE CONTROL) 3 C121 20DB/DG (3 ZONE HVAC) 3 D22 20WT/TN (AUTOMATIC TEMPERATURE CONTROL) 4 C22 20LB/WT (3 ZONE HVAC) 4 D17 20WT/DG (AUTOMATIC TEMPERATURE CONTROL) 5 C151 18LB/DG (3 ZONE HVAC) 6 - 7 C152 16LB/LG (3 ZONE HVAC) 8 E10 20OR/DG 9 Z409 20BK/OR (3 ZONE HVAC) 9 Z27 18BK/DG (AUTOMATIC TEMPERATURE CONTROL) 10 C50 12DB/OR (3 ZONE HVAC) C312 - GRAY (HEADLINER SIDE) CAV CIRCUIT 1 M27 20YL/LB 2 M22 20YL/OR 3 G23 20VT/DB (EXCEPT BASE) 4 G25 20VT/TN (EXCEPT BASE) 5 D25 20WT/VT (EXCEPT BASE) 6 A114 20GY/RD (EXCEPT BASE) 7 F503 20BK/PK (LUXURY/PREMIUM) 7 F503 20WT/PK (EXCEPT BASE) 8 - 9 P112 20BK/OR (LUXURY/PREMIUM) 10 P114 20BK/LB (LUXURY/PREMIUM) 11 M24 20YL/WT 12 Z837 20BK/OR 13 Z13 20BK/WT (EXCEPT BASE) 14 Z113 20BK (LUXURY/PREMIUM) 14 Z113 20BK/DB (EXCEPT BASE) 15 - 16 - 17 - 18 - 19 - 20 - 8W - 80 - 33 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C312 - GRAY (BODY SIDE) CAV CIRCUIT 1 M27 20YL/LB 2 M22 20YL/OR 3 G23 20VT/DB 4 G25 20VT/TN 5 D25 20WT/VT 6 A114 20GY/RD 7 F503 20WT/PK 8 - 9 P112 20TN/OR (EXCEPT BUILT-UP-EXPORT/POWER MIRRORS) (EXCEPT TOWN & COUNTRY) 9 P112 20BK/OR (EXCEPT BUILT-UP-EXPORT/POWER MIRRORS) (TOWN & COUNTRY) 10 P114 20TN/WT (EXCPET BUILT-UP-EXPORT/POWER MIRRORS) 11 M24 20YL/WT 12 Z837 20BK/WT 13 Z13 20BK/WT 14 Z113 20BK/WT 15 - 16 - 17 - 18 - 19 - 20 - C313 (REAR CONSOLE) - BLACK (BODY SIDE) CAV CIRCUIT 1 Z747 16BK/LB 2 F307 16LB/PK 3 F307 16LB/PK C313 (REAR CONSOLE) - BLACK (REAR CONSOLE SIDE) CAV CIRCUIT 1 Z747 16BK 1 Z747 16BK 2 F307 18OR 3 F307 16RD RS RS 8W-80 CONNECTOR PIN-OUTS C314 (HIGH LINE) - BLACK (BODY SIDE) CAV CIRCUIT 1 G32 20VT/LB (POWER LIFTGATE) 2 L77 18WT/BR 3 L50 18WT/TN 4 P30 20TN/DG 5 P31 20TN/DG (POWER RELEASE/ BUILT-UP-EXPORT LHD SWB GAS) 5 P31 20TN/YL (POWER RELEASE/ EXCEPT BUILT-UP-EXPORT LHD SWB GAS) 6 Q60 20OR/YL (POWER LIFTGATE) 7 Q84 18TN/GY (POWER LIFTGATE) 8 Z87 20BK/LG (POWER LIFTGATE) 9 Q83 18OR/GY (POWER LIFTGATE) 10 Z800 12BK C314 (HIGH LINE) - BLACK (LIFTGATE SIDE) CAV CIRCUIT 1 G32 20VT/LB (POWER LIFTGATE) 2 L77 18WT/BR 3 L50 18WT/TN 4 P30 20TN/DG 5 P31 20TN/YL (POWER RELEASE) 6 Q60 20OR/YL (POWER LIFTGATE) 7 Q84 18TN/GY (POWER LIFTGATE) 8 Z87 20BK/LG (POWER LIFTGATE) 9 Q83 18OR/GY (POWER LIFTGATE) 10 Z800 12BK C315 (HIGH LINE) - BLACK (BODY SIDE) CAV CIRCUIT 1 C15 12DB/WT 2 Q76 20OR/LB (POWER LIFTGATE) 3 G78 20VT/OR 4 M11 20YL/VT 5 G165 20VT/GY 6 Q85 18TN/WT (POWER LIFTGATE) 7 Q94 20TN/LG (POWER LIFTGATE) 8 W13 18BR/LG 9 F302 18GY/PK 10 Z245 18BK/GY (POWER LIFTGATE) 8W - 80 - 35 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C315 (HIGH LINE) - BLACK (LIFTGATE SIDE) CAV CIRCUIT 1 C15 12DB/WT 2 Q76 20OR/LB (POWER LIFTGATE) 3 G78 20VT/OR 4 M11 20YL/VT 5 G165 20VT/GY 6 Q85 18TN/WT (POWER LIFTGATE) 7 Q94 20TN/LG (POWER LIFTGATE) 8 W13 18BR/LG 9 F302 18GY/PK 10 Z245 18BK/GY (POWER LIFTGATE) C316 (POWER SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY SIDE) CAV CIRCUIT 1 P5 20BK/DB 2 P32 20BK/TN 3 G77 20BK/DG 4 Z825 14BK 5 - 6 - 7 G151 20BK/GY 8 D25 20BK/VT 9 - 10 A113 14BK/RD C316 (POWER SLIDING DOOR) - BLACK (LEFT SLIDING DOOR SIDE) CAV CIRCUIT 1 P5 20TN/OR 2 P32 20TN/VT 3 G77 20TN/OR 4 Z825 14BK/WT 5 - 6 - 7 G151 20VT/BR 8 D25 20WT/VT 9 - 10 A113 14WT/RD C317 (POWER SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY SIDE) CAV CIRCUIT 1 P38 20BK/DB 2 P34 20BK/TN 3 G76 20BK/DG 4 Z824 14BK 5 - 6 - 7 G152 20BK/GY 8 D25 20BK/VT 9 - 10 A113 14BK/RD RS RS 8W-80 CONNECTOR PIN-OUTS C317 (POWER SLIDING DOOR) - BLACK (RIGHT SLIDING DOOR SIDE) CAV CIRCUIT 1 P38 20TN/DB 2 P34 20TN/LB 3 G76 20TN/OR 4 Z824 14BK/WT 5 - 6 - 7 G152 20VT/GY 8 D25 20WT/VT 9 - 10 A113 14WT/RD C318 (TRAILER TOW) - BLACK (BODY SIDE) CAV CIRCUIT 1 L63 18WT/DG 2 L62 18WT/BR 3 L77 18WT/BR 4 L1 18WT/LG 5 Z363 18BK/DG 6 L50 18WT/TN C318 (TRAILER TOW) - BLACK (HARNESS SIDE) CAV CIRCUIT 1 L63 18WT/DG 1 L63 18WT/DG 2 L62 18WT/BR 3 L77 18WT/BR 3 L77 18WT/BR 4 L1 18WT/LG 5 Z363 18BK/DG 5 Z1 18BK/DG 6 L50 18WT/TN 6 L50 18WT/TN C319 (EXCEPT BUILT-UP-EXPORT/LOW LINE) BLACK (BODY SIDE) CAV CIRCUIT 1 C15 12DB/WT 2 L77 18WT/BR 3 L50 18WT/TN 4 P30 20TN/DG 5 P31 20TN/YL 6 G78 20VT/OR 7 M11 20YL/VT 8 W13 18BR/LG 9 F302 18GY/PK 10 Z800 12BK 8W - 80 - 37 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS C319 (EXCEPT BUILT-UP-EXPORT/LOW LINE) BLACK (LIFTGATE SIDE) CAV CIRCUIT 1 C15 12DB/WT 2 L77 18WT/BR 3 L50 18WT/TN 4 P30 20TN/DG 5 P31 20TN/YL 6 G78 20VT/OR 7 M11 20YL/VT 8 W13 18BR/LG 9 F302 18GY/PK 10 Z800 12BK C320 - DK. GRAY (SEAT SIDE) CAV CIRCUIT 1 Z849 14BK/OR 2 A210 14OR/RD C320 - DK. GRAY (POWER SEAT SIDE) CAV CIRCUIT 1 Z849 14BK/OR 2 A210 14OR/RD C321 - DK. GRAY ( SEAT SIDE) CAV CIRCUIT 1 Z848 18BK/OR 2 A210 14OR/RD C321 - DK. GRAY (POWER SEAT SIDE) CAV CIRCUIT 1 Z848 14BK/OR 2 A210 14OR/RD RS RS 8W-80 CONNECTOR PIN-OUTS C322 (MEMORY) - BLACK (BODY SIDE) CAV CIRCUIT 1 P69 20TN/DB (BUILT-UP-EXPORT) 1 P69 20TN/WT (EXCEPT BUILT-UP-EXPORT) 2 P67 20TN/OR 3 P64 20TN 4 P66 20TN/LG 5 P68 20TN/YL 6 P65 20TN/VT 7 D25 20WT/VT 8 P73 18TN/YL (BUILT-UP-EXPORT) 8 P73 18TN/VT (EXCEPT BUILT-UP-EXPORT) 9 P75 18TN/DB (BUILT-UP-EXPORT) 9 P75 18TN/LG (EXCEPT BUILT-UP-EXPORT) 10 P71 18TN/DG (EXCEPT BUILT-UP-EXPORT) 10 P71 18TN/GY (BUILT-UP-EXPORT) 11 P70 18TN/LB 12 P74 18TN/DB 13 P72 18TN/GY 14 - C322 (MEMORY) - BLACK (POWER SEAT SIDE) CAV CIRCUIT 1 P69 20TN/WT 2 P67 20OR 3 P64 20TN/OR 4 P66 20WT 5 P68 20YL 6 P65 20TN/YL 7 D25 20WT/VT 8 P73 18TN/LB 9 P75 18DB 10 P71 18TN/GY 11 P70 18LB 12 P74 18TN/DB 13 P72 18GY 14 - C324 (MANUAL SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY SIDE) CAV CIRCUIT 1 P5 20BK/DB 2 P32 20BK/TN 3 G77 20BK/DG 4 Z77 20BK 8W - 80 - 39 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS C324 (MANUAL SLIDING DOOR) - BLACK (LEFT MANUAL SLIDING DOOR SIDE) CAV CIRCUIT 1 P5 20BK/DB 2 P32 20BK/TN 3 G77 20BK/DG 4 Z77 20BK C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY SIDE) CAV CIRCUIT 1 P38 20BK/DB 2 P34 20BK/TN 3 G76 20BK/DG 4 Z76 20BK C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT MANUAL SLIDING DOOR SIDE) CAV CIRCUIT 1 P38 20BK/DB 2 P34 20BK/TN 3 G76 20BK/DG 4 Z76 20BK C326 - YELLOW (SEAT SIDE) CAV CIRCUIT 1 - 2 - 3 R33 18LG/WT 4 R31 18LG/OR C326 - YELLOW (SAFETY SEAT SIDE) CAV CIRCUIT 1 - 2 - 3 R33 18WT/BK (BUILT-UP-EXPORT) 3 R33 18LG/WT (EXCEPT BUILT-UP-EXPORT) 4 R31 18DG/WT (BUILT-UP-EXPORT) 4 R31 18LG/OR (EXCEPT BUILT-UP-EXPORT) C327 - YELLOW (SEAT SIDE) CAV CIRCUIT 1 - 2 - 3 R34 18LB/WT 4 R32 18LB/OR RS RS 8W-80 CONNECTOR PIN-OUTS C327 - YELLOW (SAFETY SEAT SIDE) CAV CIRCUIT 1 - 2 - 3 R34 18LB/WT (EXCEPT BUILT-UP-EXPORT) 3 R34 18WT/BK (BUILT-UP-EXPORT) 4 R32 18LB/OR (EXCEPT BUILT-UP-EXPORT) 4 R32 18DG/WT (BUILT-UP-EXPORT) C329 (DIESEL) - BLACK (BODY SIDE) CAV CIRCUIT 1 N2 18DB/YL 2 Z201 18BK/OR 3 N1 16DB/OR 4 Z201 18BK/OR 5 F853 20LG/PK 6 K900 18DB/DG C329 (DIESEL) - BLACK (LIFT PUMP SIDE) CAV CIRCUIT 1 N2 18OR 2 Z201 18OR 3 N1 16RD 4 Z201 18RD 5 F853 20RD 6 K900 18RD C330 (DIESEL) - LT. GRAY (BODY SIDE) CAV CIRCUIT 1 A119 16RD/OR 2 C41 20LB/DG 3 D21 20WT/BR 4 Z149 16BK/DB C330 (DIESEL) - GRAY (CABIN HEATER JUMPER SIDE) CAV CIRCUIT 1 A119 16RD/OR 2 C41 20LB/DG 3 D21 20WT/BR 4 Z149 16BK/DB 8W - 80 - 41 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS RS C331 (DIESEL) - BLACK (CABIN HEATER JUMPER SIDE) CAV CIRCUIT 1 A119 16RD/OR 2 C41 20LB/DG 3 D21 20WT/BR 4 Z149 16BK/DB C331 (DIESEL) - GRAY (CABIN HEATER COMPONENT SIDE) CAV CIRCUIT 1 A119 14RD/OR 2 C41 20DB/OR 3 D21 20WT/DB 4 Z149 14BK/DB C332 (ATC) - LT. GREEN (BODY SIDE) CAV CIRCUIT 1 C53 20LB 2 C169 20DB/OR 3 C51 12LB/BR 4 C59 20DB/LB 5 - 6 Z135 12BK/LB 7 C54 20LB/YL 8 C154 20LB/OR 9 - 10 C200 20LB/DG C332 (ATC) - BLACK (COMPONENT SIDE) CAV CIRCUIT 1 C53 18LB 2 C169 18LB/TN 3 C51 12DB/BR 4 C59 18DB/LB 5 - 6 Z135 12BK/LB 7 C54 18LB/YL 8 C154 18LB/GY 9 - 10 C200 18LB/DG CABIN HEATER ASSIST C1 (DIESEL) - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 - - 2 D21 20WT/DB SCI TRANSMIT 3 - - 4 - - 5 C41 20DB/OR CABIN HEATER ASSIST CONTROL 6 18RD DOSING PUMP CONTROL RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 CABIN HEATER ASSIST C2 (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 A119 14RD/OR FUSED B(+) 2 Z149 14BK/DB GROUND CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K944 20BK/GY CAMSHAFT POSITION SENSOR GROUND 2 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL 3 K342 16BR/WT ECM/PCM RELAY OUTPUT CAMSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F888 18BR/PK 8 VOLT SUPPLY 2 K900 18DB/DG SENSOR GROUND 3 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL CD CHANGER - 8 WAY CAV CIRCUIT FUNCTION 1 X40 24GY/WT AUDIO OUT RIGHT 2 E14 18OR/TN PANEL LAMPS DRIVER 3 D25 20WT/VT (EXCEPT BUILT-UP-EXPORT) PCI BUS 3 D25 20VT/YL (BUILT-UP-EXPORT) PCI BUS 4 X112 20RD IGNITION SWITCH OUTPUT 5 X41 20DG/WT AUDIO OUT LEFT 6 Z140 18BK/OR GROUND 7 Z141 18BK/TN GROUND 8 X160 20GY/YL B(+) CENTER DOME LAMP (BASE/HIGH LINE) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 20YL/OR COURTESY LAMPS DRIVER 2 Z327 20BK/OR GROUND 3 M27 20YL/LB READING LAMPS DRIVER 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS RS CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z350 20BK/TN GROUND 2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT CLOCKSPRING C1 - WHITE 6 WAY CAV CIRCUIT FUNCTION 1 X920 20GY/OR RADIO CONTROL MUX RETURN 2 X20 20GY/WT RADIO CONTROL MUX 3 X3 20DG/VT HORN SWITCH SENSE 4 V37 20VT SPEED CONTROL SWITCH SIGNAL 5 K900 20DB/DG SPEED CONTROL SWITCH GROUND 6 - - CLOCKSPRING C2 - YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 R61 18LG/PK DRIVER SQUIB 2 LINE 1 2 R63 18LG/WT DRIVER SQUIB 2 LINE 2 3 R43 18LG/BR DRIVER SQUIB 1 LINE 1 4 R45 18LG/OR DRIVER SQUIB 1 LINE 2 CLOCKSPRING C3 - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 - - 2 Z23 20BK/VT RIGHT SPEED CONTROL SWITCH GROUND 2 Z23 20BK/VT LEFT SPEED CONTROL SWITCH GROUND 3 V37 20DG/VT (EXCEPT BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL 3 V37 20DG/VT (EXCEPT BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL 3 V37 20VT/TN (BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL 3 V37 20VT/TN (BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL 4 X3 20DG/VT HORN SWITCH SENSE CLOCKSPRING C4 - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X20 20RD/BK RADIO CONTROL MUX 2 X920 20RD/DB RADIO CONTROL MUX RETURN RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 CLOCKSPRING C5 - YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 R45 18OR/LB DRIVER SQUIB 1 LINE 2 2 R43 18BK/LB DRIVER SQUIB 1 LINE 1 3 R63 18TN/LB DRIVER SQUIB 2 LINE 2 4 R61 18OR/LB DRIVER SQUIB 2 LINE 1 CLUTCH PEDAL INTERLOCK SWITCH (MTX) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T141 20YL/OR IGNITION SWITCH OUTPUT (START) 2 T751 20YL IGNITION SWITCH OUTPUT (START) CLUTCH PEDAL INTERLOCK SWITCH JUMPER (ATX) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T141 20YL/OR IGNITION SWITCH OUTPUT (START) 2 T751 20YL IGNITION SWITCH OUTPUT (START) CLUTCH PEDAL UPSTOP SWITCH (DIESEL) - RED 2 WAY CAV CIRCUIT FUNCTION 1 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE 2 Z150 20BK/LG GROUND 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS RS CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY CAV CIRCUIT FUNCTION 1 Z107 12BK/DG GROUND 2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL 3 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 4 - - 5 D25 18WT/VT PCI BUS 6 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 7 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 8 - - 9 A111 12DG/RD FUSED B(+) 10 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT (RUN) 11 - - 12 - - 13 - - 14 - - 15 - - 16 Z127 12BK/DG GROUND 17 - - 18 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 19 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL 20 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 21 - - 22 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL 23 B9 18DG/WT (3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 23 B9 18DG/LG (EXCEPT 3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 24 A107 12TN/RD FUSED B(+) CRANK CASE VENTILATION HEATER (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z153 18BK/GY GROUND 2 N1 18DB/OR FUEL HEATER RELAY OUTPUT CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO. 2 2 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1 3 Z122 18WT GROUND (DRAIN) RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 CRANKSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F888 18BR/PK 8 VOLT SUPPLY 2 K900 18DB/DG SENSOR GROUND 3 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL DATA LINK CONNECTOR - BLACK 16 WAY CAV CIRCUIT FUNCTION 1 - - 2 D25 20WT/VT PCI BUS 3 - - 4 Z11 18BK/LG GROUND 5 Z111 18BK/WT (EXCEPT BUILT-UP-EXPORT) GROUND 5 Z111 20BK/WT (BUILT-UP-EXPORT) GROUND 6 D20 20WT/LG (GAS) SCI RECEIVE 7 D21 20WT/BR (EXCEPT BUILT-UP-EXPORT) SCI TRANSMIT 7 D21 20WT/DG (BUILT- UP-EXPORT) SCI TRANSMIT 8 - - 9 D23 20WT/BR FLASH PROGRAM ENABLE 10 - - 11 - - 12 - - 13 - - 14 D16 20WT/OR (GAS) SCI RECEIVE 15 - - 16 A105 20DB/RD FUSED B(+) DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY CAV CIRCUIT FUNCTION 1 D25 20WT/VT PCI BUS (PCM/SKIM/ECM/THATCHAM) 2 D25 20WT/VT PCI BUS (HVAC) 3 D25 20WT/VT PCI BUS (RADIO) 4 D25 20WT/VT PCI BUS (ORC) 5 D25 20WT/VT PCI BUS (CLUSTER) 6 D25 20WT/VT PCI BUS (BCM) 7 D25 20WT/VT PCI BUS (DLC) 8 D25 20WT/VT PCI BUS (OVERHEAD CONSOLE) 9 D25 20WT/VT PCI BUS (FCM/TCM/CAB) 10 D25 20WT/VT PCI BUS (LSIACM) 11 D25 20WT/VT (MEMORY) PCI BUS (MEMORY) 12 D25 20WT/VT PCI BUS (PWR DOOR LT/RT/LIFTGATE) 13 D25 20WT/VT PCI BUS (RSIACM) 14 - - 15 - - 16 - - 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS RS DOSING PUMP (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 18RD DOSING PUMP CONTROL 2 Z149 18BK/DB GROUND DRIVER AIRBAG C1 - BROWN 2 WAY CAV CIRCUIT FUNCTION 1 R43 18BK/LB DRIVER SQUIB 1 LINE 1 2 R45 18OR/LB DRIVER SQUIB 1 LINE 2 DRIVER AIRBAG C2 - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 R61 18OR/LB DRIVER SQUIB 2 LINE 1 2 R63 18TN/LB DRIVER SQUIB 2 LINE 2 DRIVER BLEND DOOR ACTUATOR (ATC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C61 20DB/LG DRIVER BLEND DOOR DRIVER (A) 2 C161 20LB/WT DRIVER BLEND DOOR DRIVER (B) DRIVER BLEND DOOR ACTUATOR (MTC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C61 20LB/WT (LHD) DRIVER BLEND DOOR DRIVER (A) 1 C34 20DB/LB (RHD) COMMON DOOR DRIVER (B) 2 C61 20LB/WT(RHD) DRIVER BLEND DOOR DRIVER (A) 2 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B) RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 DRIVER DOOR COURTESY LAMP - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z322 20BK/BR (RHD) GROUND 1 Z321 20BK/BR (LHD) GROUND 2 - - 3 M21 20YL/BR COURTESY LAMPS DRIVER DRIVER DOOR LOCK SWITCH - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F304 16WT/PK (EXCEPT POWER WINDOWS) FUSED ACCESSORY RELAY OUTPUT 1 F304 16WT/PK (POWER WINDOWS) FUSED WINDOW CIRCUIT BREAKER OUTPUT 2 G160 20VT/LG (RHD) RIGHT DOOR LOCK SWITCH MUX 2 G161 20VT/DG (LHD) LEFT DOOR LOCK SWITCH MUX 3 Z460 20BK/LG (RHD) GROUND 3 Z461 20BK/DG (LHD) GROUND DRIVER HEATED SEAT BACK - GREEN 2 WAY CAV CIRCUIT FUNCTION 1 S2 18BK (RHD) DRIVER SEAT BACK HEATER GROUND 1 S2 18DG (LHD) DRIVER SEAT BACK HEATER GROUND 2 S1 18RD (RHD) DRIVER SEAT BACK HEATER B(+) DRIVER 2 S1 18DB (LHD) DRIVER SEAT BACK HEATER B(+) DRIVER DRIVER HEATED SEAT CUSHION - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 P87 16RD DRIVER SEAT CUSHION HEATER GROUND 2 P89 20GR SEAT SENSOR 5 VOLT SUPPLY 3 Z848 18BK/OR DRIVER SEAT TEMP SENSOR INPUT 4 P88 16GR DRIVER SEAT CUSHION HEATER B(+) DRIVER DRIVER HEATED SEAT MODULE C1 - GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Z849 18BK GROUND 2 P7 20LG/DG DRIVER HEATED SEAT SWITCH MUX 3 F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN) 4 A210 14OR/RD FUSED B(+) 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS RS DRIVER HEATED SEAT MODULE C2 - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 S2 18DG (LHD) DRIVER SEAT BACK HEATER GROUND 1 S2 18BK (RHD) DRIVER SEAT BACK HEATER GROUND 2 S1 18DB (LHD) DRIVER SEAT BACK HEATER B(+) DRIVER 2 S1 18RD (RHD) DRIVER SEAT BACK HEATER B(+) DRIVER DRIVER HEATED SEAT MODULE C3 - GREEN 4 WAY CAV CIRCUIT FUNCTION 1 P87 16RD DRIVER SEAT CUSHION HEATER GROUND 2 P89 20GR SEAT SENSOR 5 VOLT SUPPLY 3 Z848 18BK/OR DRIVER SEAT TEMP SENSOR INPUT 4 P88 16GR DRIVER SEAT CUSHION HEATER B(+) DRIVER DRIVER POWER SEAT FRONT RISER MOTOR - RED 2 WAY CAV CIRCUIT FUNCTION 1 P119 14LG/DG (MEMORY) SEAT FRONT UP DRIVER 1 P19 14LG/LB DRIVER FRONT UP SWITCH SENSE 2 P121 14LG/DB (MEMORY) SEAT FRONT DOWN DRIVER 2 P21 14LG/TN DRIVER FRONT DOWN SWITCH SENSE DRIVER POWER SEAT FRONT RISER POSITION SENSOR - BLACK 3 WAY CAV CIRCUIT FUNCTION A P28 20LG/BR SEAT POSITION SENSOR GROUND B P26 20LG FRONT RISER POSITION SIGNAL C P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY DRIVER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P17 14LG/DG DRIVER SEAT HORIZONTAL REARWARD SWITCH SENSE 1 P117 14LG/LB (LHD) (MEMORY) SEAT HORIZONTAL REARWARD DRIVER 1 P115 14LG (RHD) (MEMORY) SEAT HORIZONTAL FORWARD DRIVER 2 P15 14LG/WT DRIVER SEAT HORIZONTAL FORWARD SWITCH SENSE 2 P115 14LG (LHD) (MEMORY) SEAT HORIZONTAL FORWARD DRIVER 2 P117 14LG/LB (RHD) (MEMORY) SEAT HORIZONTAL REARWARD DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 DRIVER POWER SEAT HORIZONTAL POSITION SENSOR - BLACK 3 WAY CAV CIRCUIT FUNCTION A P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY B P25 20LG/VT SEAT HORIZONTAL POSITION SIGNAL C P28 20LG/BR SEAT POSITION SENSOR GROUND DRIVER POWER SEAT REAR RISER MOTOR - RED 2 WAY CAV CIRCUIT FUNCTION 1 P11 14LG/YL DRIVER SEAT REAR UP SWITCH SENSE 1 P111 14LG/YL (MEMORY) SEAT REAR UP DRIVER 2 P13 14LG/OR DRIVER SEAT REAR DOWN SWITCH SENSE 2 P113 14LG/WT (MEMORY) SEAT REAR DOWN DRIVER DRIVER POWER SEAT REAR RISER POSITION SENSOR - BLACK 3 WAY CAV CIRCUIT FUNCTION A P28 20LG/BR SEAT POSITION SENSOR GROUND B P27 20LG/LB REAR RISER POSITION SIGNAL C P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY DRIVER POWER SEAT RECLINER MOTOR - GREEN 2 WAY CAV CIRCUIT FUNCTION 1 P41 14LG/GY DRIVER SEAT RECLINER DOWN SWITCH SENSE 1 P141 14LG/BR (MEMORY) SEAT RECLINER DOWN DRIVER 2 P43 14LG/VT DRIVER SEAT RECLINER UP SWITCH SENSE 2 P143 14LG/GY (MEMORY) SEAT RECLINER UP DRIVER DRIVER POWER SEAT RECLINER POSITION SENSOR - BLACK 3 WAY CAV CIRCUIT FUNCTION A P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY B P47 20LG/LB RECLINER POSITION SIGNAL C P28 20LG/BR SEAT POSITION SENSOR GROUND 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS RS DRIVER POWER SEAT SWITCH - GREEN 10 WAY CAV CIRCUIT FUNCTION 1 Z849 20BK/OR (MEMORY) GROUND 1 Z849 14BK/OR GROUND 2 P43 14LG/VT DRIVER SEAT RECLINER UP SWITCH SENSE 2 P43 14LG/VT (MEMORY) RECLINER UP SWITCH SENSE 3 P17 14LG/DG DRIVER SEAT HORIZONTAL REARWARD SWITCH SENSE 3 P17 20LG/DG (MEMORY) SEAT HORIZONTAL REARWARD SWITCH SENSE 4 P41 14LG/GY DRIVER SEAT RECLINER DOWN SWITCH SENSE 4 P41 14LG/GY (MEMORY) RECLINER DOWN SWITCH SENSE 5 A210 14OR/RD FUSED SEAT SWITCH DRIVER 5 P9 20LG/OR (MEMORY) SEAT SWITCH B(+) SUPPLY 6 P15 14LG/WT DRIVER SEAT HORIZONTAL FORWARD SWITCH SENSE 6 P15 20LG/WT (MEMORY) SEAT HORIZONTAL FORWARD SWITCH SENSE 7 P19 14LG/LB DRIVER FRONT UP SWITCH SENSE 7 P19 20LG/LB (MEMORY) SEAT FRONT UP SWITCH SENSE 8 P11 14LG/YL DRIVER SEAT REAR UP SWITCH SENSE 8 P11 20LG/YL (MEMORY) SEAT REAR UP SWITCH SENSE 9 P13 20LG/OR (MEMORY) SEAT REAR DOWN SWITCH SENSE 9 P13 14LG/OR DRIVER SEAT REAR DOWN SWITCH SENSE 10 P21 14LG/TN DRIVER FRONT DOWN SWITCH SENSE 10 P21 20LG/TN (MEMORY) SEAT FRONT DOWN SWITCH SENSE DRIVER POWER WINDOW MOTOR - RED 2 WAY CAV CIRCUIT FUNCTION 1 Q11 16OR/LG MASTER WINDOW SWITCH DRIVER UP 2 Q21 16OR/WT MASTER WINDOW SWITCH DRIVER DOWN DRIVER POWER WINDOW SWITCH (EXCEPT LOWLINE) - GREEN 14 WAY CAV CIRCUIT FUNCTION 1 Q24 16OR/DG PASSENGER SIDE REAR WINDOW OPEN 2 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER UP 3 Q13 16OR/DB DRIVER SIDE REAR WINDOW CLOSE 4 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN 5 Q14 16OR/GY PASSENGER SIDE REAR WINDOW CLOSE 6 Q11 16OR/LG MASTER WINDOW SWITCH DRIVER UP 7 Q23 16OR/LB DRIVER SIDE REAR WINDOW OPEN 8 Q21 16OR/WT MASTER WINDOW SWITCH DRIVER DOWN 9 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 10 - - 11 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 12 - - 13 Z421 12BK/BR GROUND 14 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 DRIVER POWER WINDOW SWITCH (LOWLINE) - LT. GRAY 8 WAY CAV CIRCUIT FUNCTION 1 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 2 Z421 12BK/BR GROUND 3 Z421 12BK/BR GROUND 4 - - 5 Q21 16OR/WT MASTER WINDOW SWITCH DRIVER DOWN 6 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 7 Z421 20BK/BR GROUND 8 Q11 16OR/LG MASTER WINDOW SWITCH DRIVER UP DRIVER POWER WINDOW SWITCH (RHD) - NATURAL 14 WAY CAV CIRCUIT FUNCTION 1 Q23 16OR/LB DRIVER SIDE REAR WINDOW OPEN 2 Q11 16OR/LG MASTER WINDOW SWITCH DRIVER UP 3 Q14 16OR/GY PASSENGER SIDE REAR WINDOW CLOSE 4 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN 5 Q13 16OR/DB DRIVER SIDE REAR WINDOW CLOSE 6 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER UP 7 Q24 16OR/DG PASSENGER SIDE REAR WINDOW OPEN 8 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 9 Z421 12BK/BR GROUND 10 - - 11 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 12 - - 13 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 14 Q21 16OR/WT MASTER WINDOW SWITCH DRIVER DOWN DRIVER SEAT BELT SWITCH - WHITE 2 WAY CAV CIRCUIT FUNCTION 1 R59 18LG/TN DRIVER SEAT BELT SWITCH LINE 1 2 R57 18LG/GY DRIVER SEAT BELT SWITCH LINE 2 DRIVER SEAT BELT TENSIONER - 2 WAY CAV CIRCUIT FUNCTION 1 R53 18LG/YL DRIVER SEAT BELT TENSIONER LINE 2 2 R55 18LG/DG DRIVER SEAT BELT TENSIONER LINE 1 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS RS EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K35 20GY/YL EGR SOLENOID CONTROL 2 K342 16BR/WT ECM/PCM RELAY OUTPUT EGR SOLENOID (GAS) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K35 18DB/VT EGR SOLENOID CONTROL 2 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) ELECTRIC WIPER DE-ICER C1 - WHITE 2 WAY CAV CIRCUIT FUNCTION 1 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT 2 - - ELECTRIC WIPER DE-ICER C2 - WHITE 2 WAY CAV CIRCUIT FUNCTION 1 C900 18LB/VT WIPER DE-ICER DRIVER 2 - - RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY CAV CIRCUIT FUNCTION 1 Z130 14BK/BR GROUND 2 Z131 14BK/DG GROUND 3 K20 14BR/GY GENERATOR FIELD CONTROL 4 K342 14BR/WT ECM/PCM RELAY OUTPUT 5 K342 14BR/WT ECM/PCM RELAY OUTPUT 6 - - 7 D25 20WT/VT PCI BUS 8 K944 20BK/GY CAMSHAFT POSITION SENSOR SHIELD GROUND 9 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL 10 - - 11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL 12 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL 13 K78 20GY FUEL PRESSURE SENSOR SIGNAL 14 - - 15 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL 16 K80 20DB/TN FUEL PRESSURE SENSOR GROUND 17 - - 18 - - 19 N1 20DB/OR FUEL HEATER RELAY OUTPUT 20 Z138 20BK/OR GROUND 21 K900 20DB/DG SENSOR GROUND 22 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 23 F851 20LB/PK SENSOR REFERENCE VOLTAGE B 24 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1 25 - - 26 - - 27 - - 28 - - 29 - - 30 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL 31 F853 20LG/PK WATER IN FUEL SENSOR SIGNAL 32 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL 33 - - 34 K167 20BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND 35 K853 20DB/BR ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY 36 C18 20LB/BR A/C PRESSURE SENSOR SIGNAL 37 K89 20DB/WT ENGINE OIL TEMPERATURE SENSOR SIGNAL 38 V37 20VT/TN SPEED CONTROL SWITCH SIGNAL 39 - - 40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 41 K21 20DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 42 Z122 18WT GROUND (DRAIN) 43 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO. 2 44 - - 45 - - 46 - - 47 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT 48 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL 49 T751 20YL FUSED IGNITION SWITCH OUTPUT (START) 50 F855 20PK/YL SENSOR REFERENCE VOLTAGE A 51 - - 52 K121 20DB BOOST PRESSURE SENSOR GROUND 53 - - 54 K957 20BK/OR MASS AIR FLOW SENSOR GROUND 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS RS ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY CAV CIRCUIT FUNCTION 55 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL 56 C918 20BK/LB A/C PRESSURE SENSOR GROUND 57 - - 58 K4 20BK/LB LOW IDLE POSITION SWITCH GROUND 59 - - 60 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY 61 K51 20BR/WT ECM/PCM RELAY CONTROL 62 - - 63 D21 20WT/BR SCI TRANSMIT 64 K151 20WT LOW IDLE POSITION SWITCH SENSE 65 - - 66 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND 67 - - 68 - - 69 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL 70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL 71 - - 72 N21 20DB/TN LIFT PUMP RELAY CONTROL 73 - - 74 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL 75 - - 76 - - 77 K152 20DB/WT GLOW PLUG RELAY CONTROL 78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL 79 - - 80 K87 20BR FUEL PRESSURE SOLENOID CONTROL 81 K87 20BR FUEL PRESSURE SOLENOID CONTROL RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY CAV CIRCUIT FUNCTION 82 - - 83 - - 84 - - 85 - - 86 T753 20DG/YL FUSED IGNITION SWITCH OUTPUT (START) 87 - - 88 K35 20GY/YL EGR SOLENOID CONTROL 89 K35 20GY/YL EGR SOLENOID CONTROL 90 - - 91 - - 92 - - 93 - - 94 - - 95 - - 96 - - 97 - - 98 - - 99 - - 100 - - 101 - - 102 - - 103 - - 104 - - 105 - - 106 - - 107 - - 108 - - 109 - - 110 - - 111 - - 112 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE 113 - - 114 - - 115 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL 116 K111 14DB/LB COMMON INJECTOR DRIVER 117 - - 118 K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL 119 K12 14TN FUEL INJECTOR NO. 2 CONTROL 120 K13 14BR/LB FUEL INJECTOR NO. 3 CONTROL 121 - - ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY CAV CIRCUIT FUNCTION 1 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS RS ENGINE COOLANT TEMP SENSOR (GAS) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K900 18DB/DG SENSOR GROUND 2 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F855 20PK/YL SENSOR REFERENCE VOLTAGE A 2 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL 3 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND ENGINE OIL PRESSURE SWITCH (GAS) - LT. GREEN 2 WAY CAV CIRCUIT FUNCTION 1 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE 2 - - ENGINE OIL TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K89 20DB/WT ENGINE OIL TEMPERATURE SENSOR SIGNAL 2 K900 20DB/OR SENSOR GROUND EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL 2 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL 2 C121 20DB/DG SENSOR GROUND FLOOR CONSOLE LAMP - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F307 18OR (REAR CONSOLE) (ACCESSORY RELAY POSITION) FUSED ACCESSORY RELAY OUTPUT 1 F307 18OR (REAR CONSOLE) (BATTERY POSITION) FUSED B(+) 1 M27 18OR (FRONT CONSOLE) READING LAMPS DRIVER 2 Z747 16BK (REAR CONSOLE) GROUND 2 Z746 16BK (FRONT CONSOLE) GROUND FLOOR CONSOLE POWER OUTLET- RED 3 WAY CAV CIRCUIT FUNCTION 1 F307 16RD (REAR CONSOLE) (ACCESSORY RELAY POSITION) FUSED ACCESSORY RELAY OUTPUT 1 F307 16RD (REAR CONSOLE ) (BATTERY POSITION) FUSED B(+) 1 A105 16RD (FRONT CONSOLE) FUSED B(+) 2 - - 3 Z747 16BK (REAR CONSOLE) GROUND 3 Z746 16BK (FRONT CONSOLE) GROUND FRONT BLOWER MODULE C1 (ATC) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 - - 2 Z134 12BK/OR GROUND 3 C56 20DB/LB BLOWER MOTOR CONTROL 4 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT FRONT BLOWER MODULE C2 (ATC) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 C7 12DB (EXCEPT BUILT-UP-EXPORT) HIGH SPEED BLOWER MOTOR 1 C7 12DG (BUILT-UP-EXPORT) HIGH SPEED BLOWER MOTOR 2 C70 12DB/YL (EXCEPT BUILT-UP-EXPORT) REAR BLOWER HIGH SPEED 2 C70 12BK (BUILT-UP-EXPORT) REAR BLOWER HIGH SPEED 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS RS FRONT CIGAR LIGHTER - RED/NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT 1 F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT 2 E14 20OR/TN (BUILT-UP-EXPORT) PANEL LAMPS DRIVER 3 Z736 16BK/YL GROUND FRONT READING LAMPS/SWITCH - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 E15 20OR/DB (EXCEPT BASE) ASH/RECEIVER LAMP FEED 2 Z137 20BK/LB GROUND 3 - - 4 M27 20YL/LB READING LAMPS DRIVER 5 M24 20YL/WT COURTESY LAMPS DRIVER 6 - - FRONT WASHER PUMP MOTOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 W10 18BR FRONT WASHER PUMP MOTOR CONTROL 2 F300 18OR/PK FUSED ACCESSORY RELAY OUTPUT FUEL HEATER (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 N1 16RD FUEL HEATER RELAY OUTPUT 2 Z201 18RD GROUND FUEL INJECTOR NO. 1 (2.4L/3.3L/3.8L) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K11 16BR/YL FUEL INJECTOR NO. 1 DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K111 14DB/LB COMMON INJECTOR DRIVER 2 K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL FUEL INJECTOR NO. 2 (2.4L/3.3L/3.8L) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K12 16BR/DB FUEL INJECTOR NO. 2 DRIVER FUEL INJECTOR NO. 2 (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K111 14DB/LB COMMON INJECTOR DRIVER 2 K12 14TN FUEL INJECTOR NO. 2 CONTROL FUEL INJECTOR NO. 3 (2.4L/3.3L/3.8L) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K13 16BR/LB FUEL INJECTOR NO. 3 DRIVER FUEL INJECTOR NO. 3 (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K111 14DB/LB COMMON INJECTOR DRIVER 2 K13 14BR/LB FUEL INJECTOR NO. 3 CONTROL 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS RS FUEL INJECTOR NO. 4 (2.4L/3.3L/3.8L) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER FUEL INJECTOR NO. 4 (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K111 14DB/LB COMMON INJECTOR DRIVER 2 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL FUEL INJECTOR NO. 5 (3.3L/3.8L) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K38 16BR/OR FUEL INJECTOR NO. 5 DRIVER FUEL INJECTOR NO. 6 (3.3L/3.8L) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K58 16BR/VT FUEL INJECTOR NO. 6 DRIVER FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K80 20DB/TN FUEL PRESSURE SENSOR GROUND 2 K78 20GY FUEL PRESSURE SENSOR SIGNAL 3 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR/WT ECM/PCM RELAY OUTPUT 2 K87 16BR FUEL PRESSURE SOLENOID CONTROL FUEL PUMP MODULE - LT. GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Z201 16BK/OR (GAS) GROUND 2 Z201 18BK/OR (RHD/DIESEL) GROUND 2 Z201 20BK/DB (LHD/DIESEL) (GAS) GROUND 3 N4 18DB/WT FUEL LEVEL SENSOR SIGNAL 4 N1 16DB/OR (GAS) FUEL PUMP RELAY OUTPUT GENERATOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT 1 K342 16BR/WT (GAS) AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K20 14BR/GY (DIESEL) GENERATOR FIELD CONTROL 2 K20 18BR/GY (GAS) GENERATOR FIELD CONTROL GLOVE BOX LAMP - BLUE 2 WAY CAV CIRCUIT FUNCTION 1 M28 20YL/TN GLOVE BOX LAMP DRIVER 2 Z328 20BK/TN GROUND GLOW PLUG RELAY (DIESEL) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 A202 10RD/WT FUSED B(+) 2 K152 20DB/WT GLOW PLUG RELAY CONTROL 3 K342 16BR/WT ECM/PCM RELAY OUTPUT 4 K154 10BR/OR GLOW PLUG RELAY OUTPUT HALO LAMP - BLUE 2 WAY CAV CIRCUIT FUNCTION 1 Z326 20BK/OR GROUND 2 M26 20YL/DB HALO LAMP DRIVER 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS RS HEADLAMP SWITCH - BLACK 13 WAY CAV CIRCUIT FUNCTION 1 Z403 20BK/YL (BUILT-UP-EXPORT) GROUND 2 L78 20WT/OR (BUILT-UP-EXPORT) FUSED PARK LAMP RELAY OUTPUT 3 - - 4 Z407 18BK/OR GROUND 5 L36 20WT/DB (BUILT-UP-EXPORT) REAR FOG LAMP INDICATOR DRIVER 6 L900 20WT/YL HEADLAMP SWITCH MUX RETURN 7 L13 20WT/YL (BUILT-UP-EXPORT) HEADLAMP ADJUST SIGNAL 8 E19 20OR/BR PANEL LAMPS DRIVER (HEADLAMP SWITCH) 9 - - 10 L39 20WT/OR (HIGH LINE) FRONT FOG LAMP INDICATOR DRIVER 11 L307 20WT/BR HEADLAMP SWITCH MUX 12 E2 20OR/BR PANEL LAMPS DIMMER SIGNAL 13 - - HEADLAMP WASHER PUMP MOTOR (BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 V53 12BR/OR HEADLAMP WASHER RELAY OUTPUT 2 Z243 12BK/OR GROUND HIGH NOTE HORN - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z299 18BK/OR GROUND 2 X2 18DG/OR HORN RELAY OUTPUT HOOD AJAR SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 Z470 20BK/LB GROUND IDLE AIR CONTROL MOTOR (2.4L) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K59 18BR/DG IDLE AIR CONTROL NO. 4 DRIVER 2 K40 18BR/LG IDLE AIR CONTROL NO. 3 DRIVER 3 K60 18VT/LG IDLE AIR CONTROL NO. 2 DRIVER 4 K39 18VT/DG IDLE AIR CONTROL NO. 1 DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 IDLE AIR CONTROL MOTOR (3.3L/3.8L) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K39 18VT/DG IDLE AIR CONTROL NO. 1 DRIVER 2 K60 18VT/LG IDLE AIR CONTROL NO. 2 DRIVER IGNITION COIL (2.4L) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K17 16DB/TN IGNITION COIL NO. 2 DRIVER 2 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K19 16DB/DG IGNITION COIL NO. 1 DRIVER IGNITION COIL (3.3L/3.8L) - DK. GRAY 4 WAY CAV CIRCUIT FUNCTION 1 K18 16DB/OR IGNITION COIL NO. 3 DRIVER 2 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K19 16DB/DG IGNITION COIL NO. 1 DRIVER 4 K17 16DB/TN IGNITION COIL NO. 2 DRIVER IGNITION SWITCH - BLACK 5 WAY CAV CIRCUIT FUNCTION 1 G900 20VT/OR IGNITION SWITCH SENSE RETURN 2 G20 20VT/BR IGNITION SWITCH SENSE 3 F20 20PK/WT (LHD) FUSED IGNITION SWITCH OUTPUT (RUN-START) 3 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 4 T751 20YL FUSED IGNITION SWITCH OUTPUT (START) 5 A106 20LB/RD FUSED B(+) INLET AIR TEMPERATURE SENSOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K900 18DB/DG SENSOR GROUND 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS RS INPUT SPEED SENSOR (EATX) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 T13 18DG/VT SPEED SENSOR GROUND 2 T52 18DG/WT INPUT SPEED SENSOR SIGNAL INSTRUMENT CLUSTER - BLACK 13 WAY CAV CIRCUIT FUNCTION 1 E13 20OR/YL PANEL LAMPS DRIVER 2 L160 20WT/TN (LOW LINE) RIGHT TURN INDICATOR DRIVER 3 G7 20VT/GY (HIGH LINE) LOW OIL PRESSURE INDICATOR DRIVER 4 G3 20VT/LB (HIGH LINE) MALFUNCTION INDICATOR LAMP DRIVER 5 L134 20WT/GY (HIGH LINE) HIGH BEAM INDICATOR DRIVER 6 A701 16BR/RD FUSED B(+) (HAZARD) 7 Z108 18BK/LG GROUND 8 L161 20WT/LG (LOW LINE) LEFT TURN INDICATOR DRIVER 9 D25 20WT/VT PCI BUS 10 B25 18DG/WT (LHD BUILT-UP-EXPORT) PARK BRAKE SWITCH SENSE 10 B25 20DG/WT (RHD) PARK BRAKE SWITCH SENSE 10 B25 16DG/WT (LHD EXCEPT BUILT-UP-EXPORT) PARK BRAKE SWITCH SENSE 11 G26 20VT/OR CHIME DRIVER 12 G150 20VT/BR INSTRUMENT CLUSTER WAKE UP SENSE 13 Z18 18BK/LB GROUND INSTRUMENT PANEL SWITCH BANK - BLACK 13 WAY CAV CIRCUIT FUNCTION 1 - - 2 - - 3 P7 20LG/DG (RHD) DRIVER HEATED SEAT SWITCH 3 P8 20LG/WT (LHD) PASSENGER HEATED SEAT SWITCH 4 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 5 P8 20LG/WT (RHD) PASSENGER HEATED SEAT SWITCH 5 P7 20LG/DG (LHD) DRIVER HEATED SEAT SWITCH 6 - - 7 - - 8 L91 20WT/DB HAZARD SWITCH SENSE 9 W26 20BR/DB REAR WIPER SWITCH MUX 10 Z406 20BK/BR GROUND 11 G926 20VT/WT REAR WIPER SWITCH MUX RETURN 12 E14 20OR/TN PANEL LAMPS DRIVER 13 - - RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 INTEGRATED POWER MODULE C1 - LT. GREEN/RED 20 WAY CAV CIRCUIT FUNCTION 1 F301 18VT/PK FUSED ACCESSORY RELAY OUTPUT 2 - - 3 - - 4 L43 18WT/DB LEFT LOW BEAM DRIVER 5 Z344 16BK/TN GROUND 6 L34 16WT/GY RIGHT HIGH BEAM DRIVER 7 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE 8 L33 18WT/LG LEFT HIGH BEAM DRIVER 9 G31 18VT/LG (EXCEPT BASE) AMBIENT TEMPERATURE SENSOR SIGNAL 10 L44 16WT/TN RIGHT LOW BEAM DRIVER 11 F300 18OR/PK FUSED ACCESSORY RELAY OUTPUT 12 - - 13 Z343 18BK/LG GROUND 14 - - 15 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT) 16 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT) 17 - - 18 G931 18VT/BR (EXCEPT BASE) AMBIENT TEMPERATURE SENSOR RETURN 19 W20 18BR/YL REAR WASHER PUMP MOTOR CONTROL 20 W10 18BR FRONT WASHER PUMP MOTOR CONTROL INTEGRATED POWER MODULE C2 - GREEN/BLUE 10 WAY CAV CIRCUIT FUNCTION 1 N173 16DB/VT (GAS) RADIATOR FAN RELAY CONTROL 2 V53 12BR/OR (BUILT-UP-EXPORT) HEADLAMP WASHER RELAY OUTPUT 3 L60 18WT/TN (EXCEPT BUILT-UP-EXPORT) RIGHT FRONT TURN SIGNAL DRIVER 3 L60 16WT/TN (BUILT-UP-EXPORT) RIGHT FRONT TURN SIGNAL DRIVER 4 L13 18WT/YL (BUILT-UP-EXPORT) HEADLAMP ADJUST SIGNAL 5 X2 18DG/OR HORN RELAY OUTPUT 6 L90 18WT/OR (FOG LAMPS) FRONT FOG LAMP RELAY OUTPUT 7 L61 16WT/LG LEFT FRONT TURN SIGNAL DRIVER 8 - - 9 A112 12OR/RD FUSED B(+) 10 L89 18WT/YL (FOG LAMPS) FRONT FOG LAMP RELAY OUTPUT 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS RS INTEGRATED POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY CAV CIRCUIT FUNCTION 1 N21 20DB/TN LIFT PUMP RELAY CONTROL 2 - - 3 T751 20YL FUSED IGNITION SWITCH OUTPUT (START) 4 T2 18DG/WT TRS REVERSE SENSE 5 N2 18DB/YL LIFT PUMP RELAY OUTPUT 6 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT 8 Z114 18BK/LG GROUND 9 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL 10 A119 16RD/OR FUSED B(+) 11 C41 20LB/DG CABIN HEATER ASSIST CONTROL 12 T753 20DG/YL FUSED IGNITION SWITCH OUTPUT (START) 13 - - 14 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL 15 Z116 18BK/VT GROUND 16 K51 20BR/WT ECM/PCM RELAY CONTROL 17 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 18 - - 19 K342 16BR/WT ECM/PCM RELAY OUTPUT 20 - - INTEGRATED POWER MODULE C3 (GAS) - NATURAL/RED 20 WAY CAV CIRCUIT FUNCTION 1 Z115 20BK/OR (EATX) (3.3L/3.8L) GROUND 1 Z115 18BK/OR (EATX) (2.4L) GROUND 2 F1 18PK/WT (EATX) FCM OUTPUT (UNLOCK-RUN-START) 3 T751 18YL (EATX) FUSED IGNITION SWITCH OUTPUT (START) 4 T2 18DG/WT TRS REVERSE SENSE 5 T16 18YL/OR (EATX) TRANSMISSION CONTROL RELAY OUTPUT 6 T15 18YL/BR (EATX) TRANSMISSION CONTROL RELAY CONTROL 7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT 8 K31 18BR FUEL PUMP RELAY CONTROL 9 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL 10 A104 18YL/RD (EATX) FUSED B(+) 11 - - 12 - - 13 D25 18WT/VT (EATX) PCI BUS (EATX) 14 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL 15 Z116 18BK/VT GROUND 16 K51 18BR/WT AUTOMATIC SHUT DOWN RELAY CONTROL 17 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 18 K173 18BR/VT RADIATOR FAN RELAY CONTROL 19 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 20 A109 18OR/RD FUSED B(+) RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 INTEGRATED POWER MODULE C4 - BLUE 10 WAY CAV CIRCUIT FUNCTION 1 Z127 12BK/DG (GAS) GROUND 2 T750 12YL/GY ENGINE STARTER MOTOR RELAY OUTPUT 3 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT 3 K342 16BR/WT (GAS) AUTOMATIC SHUT DOWN RELAY OUTPUT 4 F500 16DG/PK (EXCEPT MTX) FUSED IGNITION SWITCH OUTPUT (RUN) 5 - - 6 D25 16WT/VT (ANTILOCK BRAKES) PCI BUS 7 A107 12TN/RD (ANTILOCK BRAKES) FUSED B(+) 8 A111 12DG/RD (ANTILOCK BRAKES) FUSED B(+) 9 A710 14RD/BR (DIESEL) B(+) (HAZARD FEED) 9 A701 14BR/RD (GAS) B(+) (HAZARD FEED) 10 - - INTEGRATED POWER MODULE C5 - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 A1 4RD B(+) 2 - - 3 - - 4 - - INTEGRATED POWER MODULE C6 - NATURAL 10 WAY CAV CIRCUIT FUNCTION 1 A101 12VT/RD FUSED B(+) 2 Z117 16BK/WT GROUND 3 Z118 16BK/YL GROUND 4 A110 12OR/RD (POWER SEAT) FUSED B(+) 5 - - 6 - - 7 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT 8 F307 16LB/PK (ACCESSORY RELAY POSITION) FUSED ACCESSORY RELAY OUTPUT 8 F307 16LB/PK (BATTERY POSITION) FUSED B(+) 9 A113 12WT/RD (POWER SLIDING DOOR) FUSED B(+) 10 - - 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS RS INTEGRATED POWER MODULE C7 - BLACK/RED 20 WAY CAV CIRCUIT FUNCTION 1 C16 20DB/GY (EXCEPT BUILT-UP-EXPORT) FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 1 C16 18DB/GY (BUILT-UP-EXPORT) FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 2 T141 20YL/OR (BUILT-UP-EXPORT) FUSED IGNITION SWITCH OUTPUT (START) 2 T751 20YL (EXCEPT BUILT-UP-EXPORT) FUSED IGNITION SWITCH OUTPUT (START) 3 D25 20WT/VT PCI BUS 4 L13 20WT/YL (BUILT-UP-EXPORT) HEADLAMP ADJUST SIGNAL 5 K32 18DB/YL (GAS) BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL 6 - - 7 W7 20BR/GY FRONT WIPER PARK SWITCH SENSE 8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE 9 F201 18PK/OR FCM OUTPUT (ORC RUN-START DRIVER) 10 F214 18PK/LG FCM OUTPUT (SIACM RUN-START DRIVER) 11 A106 20LB/RD FUSED B(+) 12 - - 13 F2 18PK/WT (GAS) FCM OUTPUT (UNLOCK-RUN-START) 14 - - 15 A114 16GY/RD FUSED B(+) (I.O.D.) 16 D23 20WT/BR FLASH PROGRAM ENABLE 17 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 18 X1 16DG/BR (PREMIUM 8 SPEAKER) NAME BRAND SPEAKER RELAY OUTPUT 19 X3 20DG/VT HORN SWITCH SENSE 20 F100 18PK/VT FCM OUTPUT (ORC RUN ONLY DRIVER) INTEGRATED POWER MODULE C8 - ORANGE 10 WAY CAV CIRCUIT FUNCTION 1 W3 12BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT 2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT 2 N1 16DB/OR (GAS) FUEL PUMP RELAY OUTPUT 3 A108 18LG/RD (BUILT-UP-EXPORT) FUSED B(+) 3 A108 18LG/RD FUSED B(+) 4 A103 18GY/RD FUSED B(+) 5 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT) 6 W4 12BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT 7 C51 12LB/BR (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) FUSED REAR BLOWER MOTOR RELAY OUTPUT 8 - - 9 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT) 10 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 INTEGRATED POWER MODULE C9 - BLACK 10 WAY CAV CIRCUIT FUNCTION 1 A102 12WT/RD FUSED B(+) 2 F20 18PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 3 C15 12DB/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 4 A105 18DB/RD FUSED B(+) 5 L61 18WT/LB (BUILT-UP-EXPORT) LEFT FRONT TURN SIGNAL DIVER 5 L61 18WT/LG (EXCEPT BUILT-UP-EXPORT) LEFT FRONT TURN SIGNAL DIVER 6 A701 16BR/RD FUSED B(+) (HAZARD) 6 A701 16BR/RD FUSED B(+) (HAZARD) 7 F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT 8 F30 12PK/YL (POWER WINDOWS) FUSED ACCESSORY RELAY OUTPUT 9 A115 12YL/RD (POWER LIFTGATE) FUSED B(+) 10 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT KNOCK SENSOR (2.4L) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K42 18DB/YL KNOCK SENSOR SIGNAL 2 K900 18DB/DG SENSOR GROUND KNOCK SENSOR (3.3L/3.8L) (EXCEPT BUILT-UP-EXPORT) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K42 18DB/YL KNOCK SENSOR SIGNAL 2 K900 18DB/DG SENSOR GROUND LEAK DETECTION PUMP (EXCEPT BUILT-UP-EXPORT) - LT. GRAY 4 WAY CAV CIRCUIT FUNCTION 1 K107 18VT/WT LEAK DETECTION PUMP SWITCH SENSE 2 K106 18VT/WT (2.4L EATX W/ABS) LEAK DETECTION PUMP SOLENOID CONTROL 2 K106 18VT/LB (EXCEPT 2.4L EATX W/ABS) LEAK DETECTION PUMP SOLENOID CONTROL 3 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 4 - - 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS RS LEFT B-PILLAR SWITCH (POWER SLIDING DOOR) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z61 20BK/DG GROUND 2 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT 3 G41 20VT/DG LEFT SLIDING DOOR PILLAR SWITCH MUX LEFT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Q49 18TN/WT LEFT CINCH/RELEASE MOTOR UNLATCH DRIVER 2 Z249 18BK/WT GROUND 3 Q45 18OR/GY LEFT CINCH/RELEASE MOTOR CLUTCH DRIVER 4 Q47 18TN/GY LEFT CINCH/RELEASE MOTOR LATCH DRIVER LEFT COMBINATION RELAY (TRAILER TOW) - BLACK 5 WAY CAV CIRCUIT FUNCTION 1 L63 18WT/DG LEFT REAR TURN SIGNAL DRIVER 2 Z1 18BK/DG GROUND 2 Z1 18BK/DG GROUND 3 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 4 L615 18OR LEFT COMBINATION SIGNAL 5 - - LEFT CYLINDER LOCK SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z463 20BK/LB GROUND 2 G163 20VT/LB LEFT CYLINDER LOCK SWITCH MUX LEFT DOOR SPEAKER - BLACK/RED 6 WAY CAV CIRCUIT FUNCTION 1 X153 20DG/YL (HIGH LINE) LEFT FRONT INSTRUMENT PANEL SPEAKER (+) 2 X15 16GY/DG (HIGH LINE) AMPLIFIED SPEAKER GROUND 3 X155 20DG/LB (HIGH LINE) LEFT FRONT INSTRUMENT PANEL SPEAKER (-) 4 X53 20DG LEFT FRONT SPEAKER (+) 5 X13 16DG/GY (HIGH LINE) RADIO CHOKE OUTPUT 6 X55 20DG/BR LEFT FRONT SPEAKER (-) RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 LEFT FOG LAMP (BUILT-UP-EXPORT) - WHITE 2 WAY CAV CIRCUIT FUNCTION 1 L89 18WT/YL FRONT FOG LAMP RELAY OUTPUT 2 Z349 18BK/YL GROUND LEFT FOG LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION A L89 18WT/YL FRONT FOG LAMP RELAY OUTPUT B Z349 18BK/YL GROUND LEFT FRONT DOOR AJAR SWITCH (BASE) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE 2 Z75 20BK/VT GROUND LEFT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE 2 Z75 20BK/VT GROUND 3 P1 20TN/LG LEFT FRONT DOOR UNLOCK DRIVER 4 P3 20TN/WT LEFT FRONT DOOR LOCK DRIVER LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L61 16WT/LG LEFT FRONT TURN SIGNAL DRIVER 2 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT) 3 Z377 18BK/BR GROUND 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS RS LEFT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B9 18DG/WT (3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 1 B9 18DG/LG (EXCEPT 3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL LEFT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q53 20OR LEFT FULL OPEN SWITCH SENSE 2 Z77 20BK/GY GROUND LEFT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L43 18WT/DB LEFT LOW BEAM DRIVER 2 Z343 18BK/LG GROUND 3 L33 18WT/LG LEFT HIGH BEAM DRIVER LEFT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - WHITE 3 WAY CAV CIRCUIT FUNCTION 1 Z203 16BR GROUND 2 L77 16BK FUSED PARK LAMP RELAY OUTPUT (LEFT) 3 L13 16RD HEADLAMP ADJUST SIGNAL LEFT HIGH BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z343 16BR GROUND 1 Z343 16BR GROUND 2 L33 16GY LEFT HIGH BEAM DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 LEFT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X153 20DG/YL LEFT FRONT I/P SPEAKER (+) 2 X155 20DG/LB LEFT FRONT I/P SPEAKER (-) LEFT LIFTGATE FLOOD LAMP - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z312 20BK/YL GROUND 1 Z311 20BK/VT GROUND 2 - - 3 M11 20YL/VT COURTESY LAMPS DRIVER LEFT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z343 16BR GROUND 2 L43 16WT LEFT LOW BEAM DRIVER LEFT MID READING LAMP (PREMIUM/LUXURY) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 20YL/OR COURTESY LAMPS DRIVER 2 Z327 20BK/OR GROUND 3 M27 20YL/LB READING LAMPS DRIVER LEFT PARK LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z343 16BR GROUND 2 L77 16BK FUSED PARK LAMP RELAY OUTPUT (LEFT) 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS RS LEFT POWER MIRROR - BLACK 12 WAY CAV CIRCUIT FUNCTION 1 P171 20TN/YL (BUILT-UP-EXPORT) LEFT FOLDING MIRROR UNFOLD DRIVER 2 P112 20TN/OR (EXCEPT BUILT-UP-EXPORT/MEMORY) MIRROR B(+) 3 P114 20TN/WT (EXCEPT BUILT-UP-EXPORT/MEMORY) MIRROR B(-) 4 P65 20TN/VT (MEMORY) LEFT MIRROR HORIZONTAL POSITION SIGNAL 5 P69 20TN/WT (MEMORY) LEFT MIRROR SENSOR GROUND 6 P64 20TN (MEMORY) LEFT MIRROR VERTICAL POSITION SIGNAL 7 P159 20TN/DG (BUILT-UP-EXPORT/ LHD) DRIVER FOLDING MIRROR FOLD DRIVER 7 P160 20TN/LG (BUILT-UP-EXPORT/ RHD) PASSENGER FOLDING MIRROR RELAY OUTPUT 8 Z215 20BK/LG GROUND 9 C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 10 P73 20TN/VT LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 11 P71 20TN/DG LEFT MIRROR UP DRIVER 12 P75 20TN/LG LEFT MIRROR LEFT DRIVER LEFT REAR LAMP ASSEMBLY - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 L63 18WT/DG (EXCEPT BUILT-UP-EXPORT) LEFT REAR TURN SIGNAL DRIVER 1 Z363 18BK/DG (BUILT-UP-EXPORT) GROUND 2 L62 18WT/BR (EXCEPT BUILT-UP-EXPORT) RIGHT REAR TURN SIGNAL DRIVER 2 L63 18WT/DG (BUILT-UP-EXPORT) LEFT REAR TURN SIGNAL DRIVER 3 L77 18WT/BR (EXCEPT BUILT-UP-EXPORT) FUSED PARK LAMP RELAY OUTPUT (LEFT) 3 L50 18WT/TN (BUILT-UP-EXPORT) BRAKE LAMP SWITCH OUTPUT 4 L1 18WT/LG BACK-UP LAMP DRIVER 5 Z363 18BK/DG (EXCEPT BUILT-UP-EXPORT) GROUND 5 L38 20WT/YL (BUILT-UP-EXPORT) REAR FOG LAMP SWITCH OUTPUT 6 L50 18WT/TN (EXCEPT BUILT-UP-EXPORT) PRIMARY BRAKE SWITCH SIGNAL 6 L77 18WT/BR (BUILT-UP-EXPORT) FUSED PARK RELAY OUTPUT (LEFT) LEFT REAR PILLAR SPEAKER - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X157 20DG LEFT REAR PILLAR SPEAKER (+) 2 X151 20DG/WT LEFT REAR PILLAR SPEAKER (-) LEFT REAR READING LAMP (LUXURY) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 20YL/OR COURTESY LAMPS DRIVER 2 Z327 20BK/OR GROUND 3 M27 20YL/LB READING LAMPS DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 LEFT REAR SPEAKER - BLACK/RED 6 WAY CAV CIRCUIT FUNCTION 1 X151 20DG/WT (HIGH LINE) LEFT REAR PILLAR SPEAKER (-) 2 X15 16GY/DG (HIGH LINE) AMPLIFIED SPEAKER GROUND 3 X157 20DG (HIGH LINE) LEFT REAR PILLAR SPEAKER (+) 4 X51 20DG/DB LEFT REAR SPEAKER (+) 5 X13 16DG/GY (HIGH LINE) RADIO CHOKE OUTPUT 6 X57 20DG/OR LEFT REAR SPEAKER (-) LEFT REAR VENT MOTOR - NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 Q14 16OR/BR (RHD) PASSENGER SIDE REAR WINDOW CLOSE 1 Q13 16OR/DB (LHD) DRIVER SIDE REAR WINDOW CLOSE 2 Q24 16OR/DG (RHD) PASSENGER SIDE REAR WINDOW OPEN 2 Q23 16OR/LB (LHD) DRIVER SIDE REAR WINDOW OPEN 3 - - LEFT REAR WHEEL SPEED SENSOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL LEFT REMOTE RADIO SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X20 20RD/BK RADIO CONTROL MUX 2 X920 20RD/DB RADIO CONTROL MUX RETURN LEFT REPEATER LAMP (BUILT-UP-EXPORT) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 A701 18BR/RD FUSED B(+) 2 L163 20WT/BR LEFT SIDE REPEATER LAMP FEED 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS RS LEFT SEAT AIRBAG - YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R31 18LG/OR (EXCEPT BUILT-UP-EXPORT) LEFT SEAT SQUIB LINE 1 1 R33 18WT/BK (BUILT-UP-EXPORT) LEFT SEAT SQUIB LINE 2 2 R33 18LG/WT (EXCEPT BUILT-UP-EXPORT) LEFT SEAT SQUIB LINE 2 2 R31 18DG/WT (BUILT-UP-EXPORT) LEFT SEAT SQUIB LINE 1 LEFT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW/RED 7 WAY CAV CIRCUIT FUNCTION 1 R31 18LG/OR LEFT SEAT SQUIB LINE 1 2 R33 18LG/WT LEFT SEAT SQUIB LINE 2 3 - - 4 D25 20WT/VT PCI BUS 5 F214 18PK/LG FCM OUTPUT (SIACM RUN-START DRIVER) 6 Z104 18BK/LG GROUND 7 Z104 18BK/LG GROUND LEFT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 Q45 18OR/GY LEFT CINCH/RELEASE MOTOR CLUTCH DRIVER 2 Q67 16TN/BR LEFT SLIDING DOOR OPEN DRIVER 3 Q69 16TN/OR LEFT SLIDING DOOR CLOSE DRIVER 4 - - 5 A113 14WT/RD FUSED B(+) 6 - - 7 - - 8 Z123 14BK/WT GROUND LEFT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) - BLACK/RED 20 WAY CAV CIRCUIT FUNCTION 1 Q71 20TN/VT LEFT DOOR MOTOR HALL EFFECT SUPPLY 2 - - 3 Q35 20OR/GY LEFT DOOR LOCK SENSE 4 Q55 20OR/BR LEFT DOOR IN/OUT HANDLE SWITCH SENSE 5 - - 6 - - 7 Q63 18OR/TN LEFT DOOR MOTOR CLUTCH DRIVER 8 Q47 18TN/GY LEFT CINCH/RELEASE MOTOR LATCH DRIVER 9 Q49 18TN/WT LEFT CINCH/RELEASE MOTOR UNLATCH DRIVER 10 - - 11 D25 20WT/VT PCI BUS 12 G77 20TN/OR LEFT SLIDING DOOR AJAR SWITCH SENSE 13 Q59 20OR/YL LEFT PAWL SWITCH SENSE 14 Q53 20OR LEFT FULL OPEN SWITCH SENSE 15 Z25 20BK/TN GROUND-DRIVER SIDE IDENTIFIER (LHD/RHD) 16 Q57 20OR/VT LEFT DOOR CHILD LOCKOUT SWITCH SENSE 17 Q73 20TN/YL LEFT DOOR MOTOR HALL EFFECT SIGNAL 18 - - 19 G151 20VT/BR LEFT SLIDING DOOR WAKE UP SIGNAL 20 Z25 20BK/TN GROUND RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 LEFT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 Z77 20BK/GY GROUND 2 Q59 20OR/YL LEFT PAWL SWITCH SENSE 3 G77 20TN/OR LEFT SLIDING DOOR AJAR SWITCH SENSE 4 Z77 20BK/GY GROUND 5 Q55 20OR/BR LEFT DOOR IN/OUT HANDLE SWITCH SENSE 6 Q57 20OR/VT LEFT DOOR CHILD LOCKOUT SWITCH SENSE LEFT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 P5 20TN/OR LEFT SLIDING DOOR LOCK UNLOCK DRIVER 2 P32 20TN/VT LEFT SLIDING DOOR LOCK DRIVER 3 Q35 20OR/GY LEFT DOOR LOCK SENSE 4 Z77 20BK/GY GROUND LEFT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 P5 20BK/DB LEFT SLIDING DOOR UNLOCK DRIVER 2 P32 20BK/TN LEFT SLIDING DOOR LOCK DRIVER 3 G77 20BK/DG LEFT SLIDING DOOR AJAR SWITCH SENSE 4 Z77 20BK GROUND LEFT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 - - 2 Q71 20TN/VT LEFT DOOR MOTOR HALL EFFECT SUPPLY 3 Q69 16TN/OR LEFT SLIDING DOOR CLOSE DRIVER 4 Z163 18BK/TN GROUND 5 Q63 18OR/TN LEFT DOOR MOTOR CLUTCH DRIVER 6 Q67 16TN/BR LEFT SLIDING DOOR OPEN DRIVER 7 Z33 20BK/TN GROUND 8 Q73 20TN/YL LEFT DOOR MOTOR HALL EFFECT SIGNAL LEFT SPEED CONTROL SWITCH - WHITE 2 WAY CAV CIRCUIT FUNCTION A V37 20VT/TN (BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL A V37 20DG/VT (EXCEPT BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL B Z23 20BK/VT LEFT SPEED CONTROL SWITCH GROUND 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS RS LEFT STOP/TURN SIGNAL RELAY (TRAILER TOW) - BLACK 5 WAY CAV CIRCUIT FUNCTION 1 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 1 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 2 Z1 18BK/DG GROUND 2 Z1 18BK/DG GROUND 3 L73 18YL LEFT STOP SIGNAL 4 L63 18WT/DG LEFT REAR TURN SIGNAL DRIVER 4 L63 18WT/DG LEFT REAR TURN SIGNAL DRIVER 5 L615 18OR LEFT COMBINATION SIGNAL LEFT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - ORANGE 2 WAY CAV CIRCUIT FUNCTION 1 Z343 16BR GROUND 2 L61 16YL LEFT FRONT TURN SIGNAL DRIVER LEFT VISOR/VANITY LAMP (PREMIUM/LUXURY) - BLACK 2 WAY CAV CIRCUIT FUNCTION A Z327 20BK/OR GROUND B M27 20YL/LB READING LAMP DRIVER LICENSE LAMP (MANUAL RELEASE) - DK. GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT 2 Z367 20BK/BR GROUND LICENSE LAMP (POWER LIFTGATE) - DK. GRAY 8 WAY CAV CIRCUIT FUNCTION 1 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT) 2 Z367 20BK/BR GROUND 3 P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE 4 Z430 20BK/LG GROUND 5 Q94 20TN/LG LIFTGATE CHIME DRIVER 6 Z294 20BK/LG GROUND 7 G32 20VT/LB LIFTGATE TEMPERATURE SENSOR SIGNAL 8 Z78 20BK/OR GROUND RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 LICENSE LAMP (POWER RELEASE) - DK. GRAY 4 WAY CAV CIRCUIT FUNCTION 1 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT) 2 Z367 20BK/BR GROUND 3 P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE 4 Z430 20BK/LG GROUND LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 N2 18OR LIFT PUMP RELAY OUTPUT 2 Z201 18OR GROUND LIFTGATE AJAR SWITCH (MANUAL RELEASE) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z78 20BK/OR GROUND 2 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE LIFTGATE AJAR SWITCH (POWER RELEASE) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z78 20BK/OR GROUND 2 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE 3 P31 20TN/YL LIFTGATE RELEASE DRIVER 4 Z231 20BK/YL GROUND LIFTGATE CINCH/RELEASE MOTOR (POWER LIFTGATE) - BLUE 7 WAY CAV CIRCUIT FUNCTION 1 Z78 20BK/OR GROUND 2 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE 3 Q60 20OR/YL LIFTGATE PAWL SWITCH SENSE 4 Z245 18BK/GY GROUND 5 Q85 18TN/WT LIFTGATE LATCH RELEASE DRIVER 6 Q84 18TN/GY LIFTGATE LATCH CINCH DRIVER 7 Q83 18OR/GY LIFTGATE LATCH CLUTCH DRIVER 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS RS LIFTGATE CYLINDER LOCK SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z465 20BK/GY GROUND 2 G165 20VT/GY LIFTGATE CYLINDER LOCK SWITCH MUX LIFTGATE LEFT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL 2 Q76 20OR/LB PINCH SENSOR SIGNAL LIFTGATE RIGHT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL 2 Z78 20BK/OR GROUND LOW NOTE HORN - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z298 18BK/DB GROUND 2 X2 18DG/OR HORN RELAY OUTPUT MANIFOLD ABSOLUTE PRESSURE SENSOR (GAS) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K1 18VT/BR MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL 2 K900 18DB/DG SENSOR GROUND 3 F855 18PK/YL (BUILT-UP-EXPORT) 5 VOLT SUPPLY 3 F855 18OR/PK (EXCEPT BUILT-UP-EXPORT) 5 VOLT SUPPLY RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 MASS AIR FLOW SENSOR (DIESEL) - ORANGE 5 WAY CAV CIRCUIT FUNCTION 1 - - 2 K342 16BR/WT ECM/PCM RELAY OUTPUT 3 K957 20BK/OR MASS AIR FLOW SENSOR GROUND 4 F855 20PK/YL SENSOR REFERENCE VOLTAGE A 5 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL MEMORY SEAT/MIRROR MODULE C1 - GRAY 26 WAY CAV CIRCUIT FUNCTION 1 P69 20TN/WT LEFT MIRROR SENSOR GROUND 2 P25 20LG/VT SEAT HORIZONTAL POSITION SIGNAL 3 P27 20LG/LB REAR RISER POSITION SIGNAL 4 - - 5 - - 6 P67 20OR RIGHT MIRROR VERTICAL POSITION SIGNAL 7 P64 20TN/OR LEFT MIRROR VERTICAL POSITION SIGNAL 8 P21 20LG/TN SEAT FRONT DOWN SWITCH SENSE 9 P13 20LG/OR SEAT REAR DOWN SWITCH SENSE 10 P15 20LG/WT SEAT HORIZONTAL FORWARD SWITCH SENSE 11 P43 14LG/VT RECLINER UP SWITCH SENSE 12 - - 13 - - 14 P66 20WT RIGHT MIRROR SENSOR GROUND 15 P26 20LG FRONT RISER POSITION SIGNAL 16 P47 20LG/LB RECLINER POSITION SIGNAL 17 - - 18 - - 19 P68 20YL RIGHT MIRROR HORIZONTAL POSITION SIGNAL 20 P65 20TN/YL LEFT MIRROR HORIZONTAL POSITION SIGNAL 21 P19 20LG/LB SEAT FRONT UP SWITCH SENSE 22 P11 20LG/YL SEAT REAR UP SWITCH SENSE 23 P17 20LG/DG SEAT HORIZONTAL REARWARD SWITCH SENSE 24 P41 14LG/GY RECLINER DOWN SWITCH SENSE 25 - - 26 D25 20WT/VT PCI BUS 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS RS MEMORY SEAT/MIRROR MODULE C2 - GRAY 16 WAY CAV CIRCUIT FUNCTION 1 - - 2 - - 3 P73 18TN/LB LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 4 P75 18DB LEFT MIRROR LEFT DRIVER 5 P71 18TN/GY LEFT MIRROR UP DRIVER 6 P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY 7 - - 8 - - 9 - - 10 - - 11 P70 18LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN) 12 P74 18TN/DB RIGHT MIRROR LEFT DRIVER 13 P72 18GY RIGHT MIRROR UP DRIVER 14 - - 15 - - 16 P28 20LG/BR SEAT POSITION SENSOR GROUND MEMORY SEAT/MIRROR MODULE C3 - WHITE 12 WAY CAV CIRCUIT FUNCTION 1 P111 14LG/YL SEAT REAR UP DRIVER 2 P115 14LG SEAT HORIZONTAL FORWARD DRIVER 3 P119 14LG/DG SEAT FRONT UP DRIVER 4 P113 14LG/WT SEAT REAR DOWN DRIVER 5 P121 14LG/DB SEAT FRONT DOWN DRIVER 6 - - 7 P143 14LG/GY SEAT RECLINER UP DRIVER 8 P9 20LG/OR SEAT SWITCH B(+) SUPPLY 9 - - 10 P141 14LG/BR SEAT RECLINER DOWN DRIVER 11 P117 14LG/LB SEAT HORIZONTAL REARWARD DRIVER 12 - - MEMORY SEAT/MIRROR MODULE C4 - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z849 14BK/OR GROUND 2 A210 14OR/RD FUSED B(+) MEMORY SET SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G200 20VT/BR MEMORY SELECT SWITCH MUX 2 G920 20VT/YL MEMORY SELECT SWITCH RETURN RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 MESSAGE CENTER (HIGH LINE) - WHITE 14 WAY CAV CIRCUIT FUNCTION 1 L160 20WT/TN (LHD) RIGHT TURN INDICATOR DRIVER 2 G3 20VT/LB (LHD) MALFUNCTION INDICATOR LAMP DRIVER 3 L134 20WT/GY (RHD) HIGH BEAM INDICATOR DRIVER 4 G69 20VT/WT (LHD) VTSS INDICATOR DRIVER 4 L160 20WT/TN (RHD) RIGHT TURN INDICATOR DRIVER 5 - - 6 G7 20VT/GY (LHD) LOW OIL PRESSURE INDICATOR DRIVER 7 A701 16BR/RD (LHD) FUSED B(+) (HAZARD) 8 A701 16BR/RD (RHD) FUSED B(+) (HAZARD) 9 G7 20VT/GY (RHD) LOW OIL PRESSURE INDICATOR DRIVER 10 - - 11 L161 20WT/LG (LHD) LEFT TURN INDICATOR DRIVER 11 G69 20VT/WT (RHD) VTSS INDICATOR DRIVER 12 L134 20WT/GY (LHD) HIGH BEAM INDICATOR DRIVER 13 G3 20VT/LB (RHD) MALFUNCTION INDICATOR LAMP DRIVER 14 L161 20WT/LG (RHD) LEFT TURN INDICATOR DRIVER MODE DOOR ACTUATOR (ATC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C135 20DB/GY MODE DOOR DRIVER (B) 2 C35 20LB/OR MODE DOOR DRIVER (A) MODE DOOR ACTUATOR (MTC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C34 20DB/LB COMMON DOOR DRIVER (B) 2 C35 20LB/OR MODE DOOR DRIVER (A) MULTI-FUNCTION SWITCH - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 W52 20BR/YL FRONT WIPER SWITCH MUX 2 G902 20VT/OR MULTI-FUNCTION SWITCH MUX RETURN 3 L305 20WT/LB TURN SIGNAL SWITCH MUX 4 G194 20VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS RS OUTPUT SPEED SENSOR (EATX) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 T13 18DG/VT SPEED SENSOR GROUND 2 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL OVERHEAD CONSOLE (EXCEPT BASE) - BLACK 12 WAY CAV CIRCUIT FUNCTION 1 G23 20VT/DB SLIDING DOORS OVERHEAD SWITCH MUX 2 G25 20VT/TN LIFTGATE SWITCH MUX 3 D25 20WT/VT PCI BUS 4 Z113 20BK/DB GROUND 5 A114 20GY/RD FUSED B(+) (I.O.D.) 6 F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN) 7 Z13 20BK/WT GROUND 8 E15 20OR/DB ASH/RECEIVER LAMP FEED 9 - - 10 - - 11 L24 20BK/GY (EXCEPT BUILT-UP-EXPORT) (PREMIUM/ LUXURY) AUTOMATIC HEADLAMP SWITCH SENSOR 12 L1 20BK/WT (PREMIUM/LUXURY) BACK-UP LAMP FEED RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY CAV CIRCUIT FUNCTION 1 - - 2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT 3 - - 4 K342 16BR/WT ECM/PCM RELAY OUTPUT 5 - - 6 N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL 7 - - 8 A201 12RD/LG FUSED B(+) 9 - - OXYGEN SENSOR 1/1 UPSTREAM (GAS) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K99 18BR/LG OXYGEN SENSOR 1/1 HEATER CONTROL 2 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K902 18BR/DG OXYGEN SENSOR 1/1 GROUND 4 K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 OXYGEN SENSOR 1/2 DOWNSTREAM (GAS) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z43 18BK/DB GROUND 2 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K902 18BR/DG OXYGEN SENSOR 1/2 GROUND 4 K141 18DB/YL OXYGEN SENSOR 1/2 SIGNAL PARK/NEUTRAL POSITION SWITCH (ATX) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z252 18BK/WT GROUND 2 T41 18YL/DB PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41) 3 T2 18DG/WT TRS REVERSE SENSE PASSENGER AIRBAG - YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 R42 18LB/BR PASSENGER SQUIB 1 LINE 2 2 R44 18LB/OR PASSENGER SQUIB 1 LINE 1 3 R62 18LB/PK PASSENGER SQUIB 2 LINE 2 4 R64 18LB/WT PASSENGER SQUIB 2 LINE 1 PASSENGER BLEND DOOR ACTUATOR (ATC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C133 20DB/WT PASSENGER BLEND DOOR DRIVER (B) 2 C33 20LB/BR PASSENGER BLEND DOOR DRIVER (A) PASSENGER BLEND DOOR ACTUATOR (MTC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C33 20LB/BR (RHD) PASSENGER BLEND DOOR DRIVER (A) 1 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B) 2 C34 20DB/LB (RHD) COMMON DOOR DRIVER (B) 2 C33 20LB/BR (LHD) PASSENGER BLEND DOOR DRIVER (A) 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS RS PASSENGER DOOR COURTESY LAMP - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z321 20BK/BR (RHD) GROUND 1 Z322 20BK/BR (LHD) GROUND 2 - - 3 M21 20YL/BR COURTESY LAMPS DRIVER PASSENGER DOOR LOCK SWITCH - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F304 16WT/PK (EXCEPT POWER WINDOWS) FUSED ACCESSORY RELAY OUTPUT 1 F304 16WT/PK (POWER WINDOWS) FUSED WINDOW CIRCUIT BREAKER OUTPUT 2 G161 20VT/DG (RHD) LEFT DOOR LOCK SWITCH MUX 2 G160 20VT/LG (LHD) RIGHT DOOR LOCK SWITCH MUX 3 Z461 20BK/DG (RHD) GROUND 3 Z460 20BK/LG (LHD) GROUND PASSENGER FOLDING MIRROR RELAY (BUILT-UP-EXPORT) - BLUE 9 WAY CAV CIRCUIT FUNCTION 1 - - 2 - - 3 - - 4 A108 18LG/RD FUSED B(+) 5 P164 18LG/DB PASSENGER FOLDING MIRROR RELAY INPUT 6 P162 18LG/DG PASSENGER FOLDING MIRROR RELAY CONTROL 7 - - 8 P160 18TN/LG PASSENGER FOLDING MIRROR RELAY OUTPUT 9 - - PASSENGER HEATED SEAT BACK - GREEN 2 WAY CAV CIRCUIT FUNCTION 1 S1 18WT (RHD) PASSENGER SEAT BACK HEATER B(+) DRIVER 1 S2 18GY (LHD) PASSENGER SEAT BACK HEATER GROUND 2 S2 18GY (RHD) PASSENGER SEAT BACK HEATER GROUND 2 S1 18WT (LHD) PASSENGER SEAT BACK HEATER B(+) DRIVER PASSENGER HEATED SEAT CUSHION - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 P87 16LG/OR PASSENGER SEAT CUSHION HEATER GROUND 2 P89 20LG/BR SEAT SENSOR 5 VOLT SUPPLY 3 Z848 18BK/OR PASSENGER SEAT TEMP SENSOR INPUT 4 P88 16LG/LB PASSENGER SEAT CUSHION HEATER B(+) DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 PASSENGER HEATED SEAT MODULE C1 - GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Z848 18BK/OR GROUND 2 P8 20LG/WT PASSENGER HEATED SEAT SWITCH MUX 3 F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN) 4 A210 14OR/RD FUSED B(+) PASSENGER HEATED SEAT MODULE C2 - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 S2 18GY PASSENGER SEAT BACK HEATER GROUND 2 S1 18WT PASSENGER SEAT BACK HEATER B(+) DRIVER PASSENGER HEATED SEAT MODULE C3 - GREEN 4 WAY CAV CIRCUIT FUNCTION 1 P87 16LG/OR PASSENGER SEAT CUSHION HEATER GROUND 2 P89 20LG/BR SEAT SENSOR 5 VOLT SUPPLY 3 Z848 18BK/OR PASSENGER SEAT TEMP SENSOR INPUT 4 P88 16LG/LB PASSENGER SEAT CUSHION HEATER B(+) DRIVER PASSENGER POWER SEAT FRONT RISER MOTOR - RED 2 WAY CAV CIRCUIT FUNCTION 1 P18 14LG/OR PASSENGER FRONT UP SWITCH SENSE 2 P20 14LG/LB PASSENGER FRONT DOWN SWITCH SENSE 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS RS PASSENGER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P14 14LG/OR PASSENGER HORIZONTAL FORWARD SWITCH SENSE 2 P16 14LG/WT PASSENGER HORIZONTAL REARWARD SWITCH SENSE PASSENGER POWER SEAT REAR RISER MOTOR - RED 2 WAY CAV CIRCUIT FUNCTION 1 P10 14LG/TN PASSENGER REAR UP SWITCH SENSE 2 P12 14LG/YL PASSENGER REAR DOWN SWITCH SENSE PASSENGER POWER SEAT RECLINER MOTOR - GREEN 2 WAY CAV CIRCUIT FUNCTION 1 P44 14LG/VT PASSENGER RECLINER UP SWITCH SENSE 2 P42 14LG/GY PASSENGER RECLINER DOWN SWITCH SENSE PASSENGER POWER SEAT SWITCH - GREEN 10 WAY CAV CIRCUIT FUNCTION 1 Z848 14BK/OR GROUND 2 P44 14LG/VT PASSENGER RECLINER UP SWITCH SENSE 3 P16 14LG/WT PASSENGER HORIZONTAL REARWARD SWITCH SENSE 4 P42 14LG/GY PASSENGER RECLINER DOWN SWITCH SENSE 5 A210 14OR/RD FUSED B(+) 6 P14 14LG/OR PASSENGER HORIZONTAL FORWARD SWITCH SENSE 7 P20 14LG/LB PASSENGER FRONT DOWN SWITCH SENSE 8 P12 14LG/YL PASSENGER REAR DOWN SWITCH SENSE 9 P10 14LG/TN PASSENGER REAR UP SWITCH SENSE 10 P18 14LG/OR PASSENGER FRONT UP SWITCH SENSE PASSENGER POWER WINDOW MOTOR - RED 2 WAY CAV CIRCUIT FUNCTION 1 Q12 14OR/BR PASSENGER WINDOW DRIVER UP 2 Q22 14OR/VT PASSENGER WINDOW DRIVER DOWN RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 PASSENGER POWER WINDOW SWITCH - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 F304 12WT/PK (EXCEPT BUILT-UP-EXPORT RHD) FUSED WINDOW CIRCUIT BREAKER OUTPUT 1 F304 16WT/PK (BUILT-UP-EXPORT LHD) FUSED WINDOW CIRCUIT BREAKER OUTPUT 2 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN 3 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER UP 4 - - 5 Q22 14OR/VT PASSENGER WINDOW DRIVER DOWN 6 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 7 Z422 20BK/BR GROUND 8 Q12 14OR/BR PASSENGER WINDOW DRIVER UP PASSENGER SEAT BELT SWITCH - 2 WAY CAV CIRCUIT FUNCTION 1 R60 18LB/TN PASSENGER SEAT BELT SWITCH LINE 1 2 R58 18LB/GY PASSENGER SEAT BELT SWITCH LINE 2 PASSENGER SEAT BELT TENSIONER - 2 WAY CAV CIRCUIT FUNCTION 1 R54 18LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 2 R56 18LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 POWER FOLDING MIRROR SWITCH (BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P136 20TN/YL FOLDING MIRROR SWITCH SENSE 2 Z888 20BK/YL GROUND 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS RS POWER LIFTGATE MODULE C1 - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 Q83 18OR/GY LIFTGATE LATCH CLUTCH DRIVER 2 Q88 16TN/BR (EXCEPT BUILT-UP-EXPORT) LIFTGATE OPEN DRIVER 2 Q88 14TN/BR (BUILT-UP-EXPORT) LIFTGATE OPEN DRIVER 3 Q89 16TN/OR (EXCEPT BUILT-UP-EXPORT) LIFTGATE CLOSE DRIVER 3 Q89 14TN/OR (BUILT-UP-EXPORT) LIFTGATE CLOSE DRIVER 4 - - 5 A115 12YL/RD FUSED B(+) 6 - - 7 - - 8 Z125 14BK/WT GROUND POWER LIFTGATE MODULE C2 - BLACK/RED 20 WAY CAV CIRCUIT FUNCTION 1 Q90 20TN/VT LIFTGATE HALL EFFECT SIGNAL 2 - - 3 Q151 20TN/DB LIFTGATE ENGAGE/DISENGAGE SWITCH SENSE 4 - - 5 Q76 20OR/LB PINCH SENSOR SIGNAL 6 - - 7 Q86 18OR/DB LIFTGATE GEAR ENGAGE DRIVER 8 Q84 18TN/GY LIFTGATE LATCH CINCH DRIVER 9 Q85 18TN/WT LIFTGATE LATCH RELEASE DRIVER 10 Q87 18OR/LG LIFTGATE GEAR DISENGAGE DRIVER 11 D25 20WT/VT PCI BUS 12 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE 13 Q60 20OR/YL LIFTGATE PAWL SWITCH SENSE 14 Q51 20OR LIFTGATE FULL OPEN SWITCH SENSE 15 - - 16 G32 20VT/LB LIFTGATE TEMPERATURE SENSOR SIGNAL 17 Q91 20TN/LG LIFTGATE HALL EFFECT SIGNAL 18 Q94 20TN/LG LIFTGATE CHIME DRIVER 19 G153 20VT/YL LIFTGATE MODULE WAKE UP SIGNAL 20 Z87 20BK/LG GROUND POWER LIFTGATE MOTOR - BLACK 10 WAY CAV CIRCUIT FUNCTION 1 Z78 20BK/OR (EXCEPT BUILT-UP-EXPORT) GROUND 1 Z87 20BK/LG (BUILT-UP-EXPORT) GROUND 2 Q51 20OR LIFTGATE FULL OPEN SWITCH SENSE 3 Q151 20TN/DB LIFTGATE ENGAGE/DISENGAGE SWITCH SENSE 4 Q87 18OR/LG LIFTGATE GEAR DISENGAGE DRIVER 5 Q86 18OR/DB LIFTGATE GEAR ENGAGE DRIVER 6 Q88 16TN/BR (EXCEPT BUILT-UP-EXPORT) LIFTGATE OPEN DRIVER 6 Q88 14TN/BR (BUILT-UP-EXPORT) LIFTGATE OPEN DRIVER 7 Q90 20TN/VT LIFTGATE HALL EFFECT SUPPLY 8 Q91 20TN/LG LIFTGATE HALL EFFECT SIGNAL 9 Z87 20BK/LG GROUND 10 Q89 16TN/OR (EXCEPT BUILT-UP-EXPORT) LIFTGATE CLOSE DRIVER 10 Q89 14TN/OR (BUILT-UP-EXPORT) LIFTGATE CLOSE DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 POWER MIRROR SWITCH - BLACK 13 WAY CAV CIRCUIT FUNCTION 1 P70 18TN/LB (MEMORY) RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN) 1 P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN) 2 - - 3 - - 4 - - 5 E18 20OR/LB PANEL LAMPS DRIVER 6 P73 20TN/VT LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 6 P73 18TN/VT (MEMORY) LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 7 P75 18TN/LG (MEMORY) LEFT MIRROR LEFT DRIVER 7 P75 20TN/LG LEFT MIRROR LEFT DRIVER 8 P74 18TN/DB (MEMORY) RIGHT MIRROR LEFT DRIVER 8 P74 20TN/DB RIGHT MIRROR LEFT DRIVER 9 A108 18LG/RD FUSED B(+) 10 - - 11 Z408 18BK/LG GROUND 12 P71 20TN/DG LEFT MIRROR UP DRIVER 12 P71 18TN/DG (MEMORY) LEFT MIRROR UP DRIVER 13 P72 18TN/GY (MEMORY) RIGHT MIRROR UP DRIVER 13 P72 20TN/GY RIGHT MIRROR UP DRIVER POWER OUTLET - NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 A105 16DB/RD FUSED B(+) 2 - - 3 Z738 16BK/WT GROUND POWER SEAT CIRCUIT BREAKER (30A) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 A110 12OR/RD FUSED B(+) 2 A210 14OR/RD FUSED SEAT SWITCH DRIVER 2 A210 14OR/RD FUSED SEAT SWITCH DRIVER POWER WINDOW CIRCUIT BREAKER (25A) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 F30 12PK/YL FUSED ACCESSORY RELAY OUTPUT 2 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS RS POWER WINDOW SWITCH (LOWLINE) - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 2 Z421 12BK/BR GROUND 3 Z421 12BK/BR GROUND 4 - - 5 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN 6 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT 7 Z421 20BK/BR GROUND 8 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER UP POWERTRAIN CONTROL MODULE C1 (GAS) - GRAY/BLACK 40-WAY CAV CIRCUIT FUNCTION 1 - - 2 K18 16DB/OR (3.3L/3.8L) IGNITION COIL NO. 3 DRIVER 3 K17 16DB/TN IGNITION COIL NO. 2 DRIVER 4 - - 5 V32 18VT/YL SPEED CONTROL ON/OFF SWITCH SENSE 6 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT 7 K13 16BR/LB FUEL INJECTOR NO. 3 DRIVER 8 K20 18BR/GY GENERATOR FIELD CONTROL 9 - - 10 Z130 18BK/BR GROUND 11 K19 16DB/DG IGNITION COIL NO. 1 DRIVER 12 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE 13 K11 16BR/YL FUEL INJECTOR NO. 1 DRIVER 14 K58 16BR/VT (3.3L/3.8L) FUEL INJECTOR NO. 6 DRIVER 15 K38 16BR/OR (3.3L/3.8L) FUEL INJECTOR NO. 5 DRIVER 16 K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER 17 K12 16BR/DB FUEL INJECTOR NO. 2 DRIVER 18 K99 18BR/LG OXYGEN SENSOR 1/1 HEATER CONTROL 19 - - 20 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 21 - - 22 - - 23 - - 24 - - 25 K42 18DB/YL (EXCEPT 3.3L/3.8L BUILT-UP-EXPORT) KNOCK SENSOR SIGNAL 26 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 27 K902 18BR/DG OXYGEN SENSOR GROUND 28 - - 29 - - 30 K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL 31 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL 32 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL 33 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL 34 - - 35 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL 36 K1 18VT/BR MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL 37 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 38 - - 39 - - 40 K35 18DB/VT EGR SOLENOID CONTROL RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 95 POWERTRAIN CONTROL MODULE C2 (GAS) - GRAY/GRAY 40 WAY CAV CIRCUIT FUNCTION 41 V37 18VT SPEED CONTROL SWITCH SIGNAL 42 C18 18LB/BR A/C PRESSURE SENSOR SIGNAL 43 K900 18DB/DG SENSOR GROUND 44 F888 18BR/PK 8 VOLT SUPPLY 45 - - 46 A109 18OR/RD FUSED B(+) 47 - - 48 K40 18BR/LG (2.4L) IDLE AIR CONTROL NO. 3 DRIVER 49 K60 18VT/LG (2.4L) IDLE AIR CONTROL NO. 2 DRIVER 49 K39 18VT/DG (3.3L/3.8L) IDLE AIR CONTROL NO. 1 DRIVER 50 Z131 18BK/DG GROUND 51 K141 18DB/YL OXYGEN SENSOR 1/2 SIGNAL 52 - - 53 - - 54 - - 55 - - 56 V36 18VT/YL SPEED CONTROL VACUUM SOLENOID CONTROL 57 K39 18VT/DG (2.4L) IDLE AIR CONTROL NO. 1 DRIVER 57 K60 18VT/LG (3.3L/3.8L) IDLE AIR CONTROL NO. 2 DRIVER 58 K59 18BR/DG (2.4L) IDLE AIR CONTROL NO. 4 DRIVER 59 D25 18WT/VT PCI BUS 60 - - 61 F855 18PK/YL 5 VOLT SUPPLY 62 B29 18DG/WT SECONDARY BRAKE SWITCH SIGNAL 63 T10 18DG/LG (EATX) TORQUE MANAGEMENT REQUEST SENSE 64 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL 65 D21 18WT/BR SCI TRANSMIT 66 N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL 67 K51 18BR/WT AUTOMATIC SHUT DOWN RELAY CONTROL 68 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL 69 - - 70 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE 71 - - 72 K107 18VT/WT (EXCEPT BUILT-UP-EXPORT) LEAK DETECTION PUMP SWITCH SENSE 73 K173 18BR/VT RADIATOR FAN RELAY CONTROL 74 K31 18BR FUEL PUMP RELAY CONTROL 75 D20 18WT/LG SCI RECEIVE 76 T41 18YL/DB PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41) 77 K106 18VT/WT (EXCEPT BUILT-UP-EXPORT) (2.4L EATX W/ABS) LEAK DETECTION PUMP SOLENOID CONTROL 77 K106 18VT/LB (EXCEPT BUILT-UP-EXPORT) (EXCEPT 2.4L EATX W/ABS) LEAK DETECTION PUMP SOLENOID CONTROL 78 K54 18DB/WT (ATX) TORQUE CONVERTER CLUTCH SOLENOID CONTROL 79 - - 80 V35 18VT/OR SPEED CONTROL VENT SOLENOID CONTROL 8W - 80 - 96 8W-80 CONNECTOR PIN-OUTS RS RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL 2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT RADIATOR FAN NO. 1 (GAS) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 N23 12DB/DG RADIATOR FAN RELAY OUTPUT 2 Z223 12BK/DG GROUND RADIATOR FAN NO. 2 (DIESEL) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z823 12BK GROUND 2 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT RADIATOR FAN NO. 2 (GAS) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 N23 12DB/DG RADIATOR FAN RELAY OUTPUT 2 Z223 12BK/DG GROUND RADIATOR FAN RELAY (GAS) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 A112 12OR/RD FUSED B(+) 2 N23 12DB/DG RADIATOR FAN RELAY OUTPUT 3 Z723 18BK/DG GROUND 4 N173 16DB/VT RADIATOR FAN RELAY CONTROL RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97 RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY CAV CIRCUIT FUNCTION 1 - - 2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT 3 - - 4 K342 16BR/WT ECM/PCM RELAY OUTPUT 5 - - 6 N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL 7 - - 8 A201 12RD/LG FUSED B(+) 9 - - RADIATOR FAN RELAY NO. 2 (DIESEL) - BLUE 9 WAY CAV CIRCUIT FUNCTION 1 - - 2 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT 3 - - 4 K342 16BR/WT ECM/PCM RELAY OUTPUT 5 - - 6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL 7 - - 8 A112 12OR/RD FUSED B(+) 9 - - RADIATOR FAN RELAY NO. 3 (DIESEL) - BLUE 9 WAY CAV CIRCUIT FUNCTION 1 - - 2 Z823 12BK GROUND 3 - - 4 K342 16BR/WT ECM/PCM RELAY OUTPUT 5 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT 6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL 7 - - 8 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL 9 - - 8W - 80 - 98 8W-80 CONNECTOR PIN-OUTS RS RADIO C1 - 22 WAY CAV CIRCUIT FUNCTION 1 A114 16GY/RD FUSED B(+) (I.O.D.) 2 F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT 3 E14 20OR/TN PANEL LAMPS DRIVER 4 - - 5 - - 6 - - 7 X56 20GY/BR (EXCEPT BUILT-UP-EXPORT) RIGHT FRONT SPEAKER (-) 7 X54 20GY (BUILT-UP-EXPORT) RIGHT FRONT SPEAKER (-) 7 X156 20GY/LB (LOW LINE) RIGHT FRONT I/P SPEAKER (-) 8 X154 20GY/YL (LOW LINE) RIGHT FRONT I/P SPEAKER (+) 8 X56 20GY/BR (BUILT-UP-EXPORT) RIGHT FRONT SPEAKER (+) 8 X54 20GY (EXCEPT BUILT-UP-EXPORT) RIGHT FRONT SPEAKER (+) 9 X55 20DG/BR LEFT FRONT SPEAKER (-) 9 X155 20DG/LB (LOW LINE) LEFT FRONT I/P SPEAKER (-) 10 X53 20DG LEFT FRONT SPEAKER (+) 10 X153 20DG/YL (LOW LINE) LEFT FRONT I/P SPEAKER (+) 11 Z514 16BK/LG (BUILT-UP-EXPORT) GROUND 11 Z333 16BK/PK (EXCEPT BUILT-UP-EXPORT) GROUND 12 A114 16GY/RD (EXCEPT BUILT-UP-EXPORT) FUSED B(+) (I.O.D.) 13 X60 20GY/YL (BUILT-UP-EXPORT) RADIO 12 VOLT OUTPUT 14 D25 18WT/VT (EXCEPT BUILT-UP-EXPORT) PCI BUS 14 D25 20WT/VT (BUILT-UP-EXPORT) PCI BUS 15 - - 16 - - 17 - - 18 X51 20DG/DB LEFT REAR SPEAKER (+) 19 X57 20DG/OR LEFT REAR SPEAKER (-) 20 X58 20GY/OR RIGHT REAR SPEAKER (-) 21 X52 20GY/DB RIGHT REAR SPEAKER (+) 22 Z515 16BK (BUILT-UP-EXPORT) GROUND 22 Z222 16BK/LG (EXCEPT BUILT-UP-EXPORT) GROUND RADIO C2 - 8 WAY CAV CIRCUIT FUNCTION 1 X40 20GY/WT AUDIO OUT RIGHT 2 E14 18OR/TN PANEL LAMPS DRIVER 3 D25 20WT/VT (EXCEPT BUILT-UP-EXPORT) PCI BUS 3 D25 20VT/YL (BUILT-UP-EXPORT) PCI BUS 4 X112 20RD IGNITION SWITCH OUTPUT 5 X41 20DG/WT AUDIO OUT LEFT 6 Z140 18BK/OR GROUND 7 Z141 18BK/TN GROUND 8 X160 20GY/YL B(+) RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99 RADIO CHOKE - LT. GRAY 2 WAY CAV CIRCUIT FUNCTION 1 X1 16DG/BR NAME BRAND SPEAKER RELAY OUTPUT 2 X13 16DG/GY RADIO CHOKE OUTPUT REAR A/C-HEATER UNIT (3 ZONE HVAC) - LT. GREEN 10 WAY CAV CIRCUIT FUNCTION 1 C53 20LB REAR MODE DOOR DRIVER 2 C154 20LB/OR REAR COMMON DOOR DRIVER 3 C51 12LB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT 4 C152 16LB/LG REAR BLOWER MOTOR MED 5 C151 18LB/DG REAR BLOWER MOTOR LOW 6 C153 12DB/BR REAR BLOWER MOTOR HIGH 7 C54 20LB/YL REAR BLEND DOOR DRIVER 8 C154 20LB/OR REAR COMMON DOOR DRIVER 9 - - 10 C200 20LB/DG TXV SOLENOID FEED REAR AUTO TEMP CONTROL SWITCH (ATC) - BLACK 13 WAY CAV CIRCUIT FUNCTION 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 Z27 18BK/DG GROUND 3 D22 20WT/TN KDB CLOCK 4 D17 20WT/DG KDB DATA 5 E10 20OR/DG PANEL LAMPS DRIVER 6 - - 7 - - 8 - - 9 - - 10 - - 11 - - 12 - - 13 - - REAR BLOWER FRONT CONTROL SWITCH (3 ZONE HVAC) - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 - - 2 Z440 12BK/DG GROUND 3 - - 4 C153 12DB/BR REAR BLOWER MOTOR HIGH 5 - - 6 C152 16LB/LG REAR BLOWER MOTOR MED 7 C151 18LB/DG REAR BLOWER MOTOR LOW 8 C50 12DB/OR REAR BLOWER FRONT CONTROL FEED 8W - 80 - 100 8W-80 CONNECTOR PIN-OUTS RS REAR BLOWER MOTOR POWER MODULE C1 (ATC) - RED/BLACK 4 WAY CAV CIRCUIT FUNCTION 1 C51 18DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT 1 C51 12DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT 2 C59 18DB/LB BLOWER MOTOR CONTROL 3 Z135 12BK/LB GROUND 4 - - REAR BLOWER MOTOR POWER MODULE C2 (ATC) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 12BK GROUND 2 12DG POWER FEED REAR BLOWER REAR CONTROL SWITCH C1 (3 ZONE HVAC) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 C153 12DB/BR REAR BLOWER MOTOR HIGH 2 C152 16LB/LG REAR BLOWER MOTOR MED 3 C151 18LB/DG REAR BLOWER MOTOR LOW 4 C50 12DB/OR REAR BLOWER FRONT CONTROL FEED REAR BLOWER REAR CONTROL SWITCH C2 (3 ZONE HVAC) - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 - - 2 C22 20LB/DB REAR TEMPERATURE FEEDBACK SIGNAL 3 E10 20OR/DG PANEL LAMPS DRIVER 4 F850 20LB/PK 5 VOLT SUPPLY 5 C121 20DB/DG REAR TEMPERATURE RETURN 6 Z409 20BK/OR GROUND REAR DOME LAMP (EXCEPT LUXURY) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 20YL/OR COURTESY LAMPS DRIVER 2 Z327 20BK/OR GROUND 3 - - RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 101 REAR MODE MOTOR (ATC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C154 18LB/GY REAR MODE DOOR DRIVER (B) 2 C53 18LB REAR MODE DOOR DRIVER (A) REAR POWER OUTLET - RED 3 WAY CAV CIRCUIT FUNCTION 1 F307 16LB/PK (ACCESSORY RELAY POSITION) FUSED ACCESSORY RELAY OUTPUT 1 F307 16LB/PK (BATTERY POSITION) FUSED B(+) 2 - - 3 Z737 16BK/LB GROUND REAR TEMPERATURE MOTOR (ATC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C54 18LB/YL REAR BLEND DOOR DRIVER (A) 2 C169 18LB/TN REAR BLEND DOOR DRIVER (B) REAR WASHER PUMP MOTOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 W20 18BR/YL REAR WASHER PUMP MOTOR CONTROL 2 F301 18VT/PK FUSED ACCESSORY RELAY OUTPUT REAR WIPER MOTOR - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z213 18BK/LG GROUND 2 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT 3 W13 18BR/LG REAR WIPER MOTOR CONTROL 8W - 80 - 102 8W-80 CONNECTOR PIN-OUTS RS RECIRCULATION DOOR ACTUATOR (ATC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C132 20DB/YL RECIRCULATION DOOR DRIVER (B) 2 C32 20DB/TN RECIRCULATION DOOR DRIVER (A) RECIRCULATION DOOR ACTUATOR (MTC) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C32 20DB/TN (RHD) RECIRCULATION DOOR DRIVER (A) 1 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B) 2 C34 20DB/LB (RHD) COMMON DOOR DRIVER (B) 2 C32 20DB/TN (LHD) RECIRCULATION DOOR DRIVER (A) REMOTE KEYLESS ENTRY ANTENNA (JAPAN) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 D10 18WT REMOTE KEYLESS ENTRY ANTENNA (+) 2 D10 18WT/LB REMOTE KEYLESS ENTRY ANTENNA (-) REMOTE KEYLESS ENTRY MODULE - BLACK/RED 6 WAY CAV CIRCUIT FUNCTION 1 G96 20VT/DG REMOTE KEYLESS ENTRY INTERFACE 2 D9 20WT/GY RKE MODULE PROGRAM ENABLE 3 Z109 20BK/GY GROUND 4 D10 18WT (RHD) (JAPAN ONLY) REMOTE KEYLESS ENTRY ANTENNA (+) 5 D10 18WT/LB (RHD) (JAPAN ONLY) REMOTE KEYLESS ENTRY ANTENNA (-) 6 A114 20GY/RD FUSED B(+) (I.O.D.) RIGHT B-PILLAR SWITCH (POWER SLIDING DOOR) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z62 20BK/YL GROUND 2 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT 3 G42 20VT/YL (EXCEPT TOWN & COUNTRY) RIGHT SLIDING DOOR PILLAR SWITCH MUX 3 G42 20VT/WT (TOWN & COUNTRY) RIGHT SLIDING DOOR PILLAR SWITCH MUX RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 103 RIGHT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER 2 Z248 18BK/WT GROUND 3 Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER 4 Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER RIGHT COMBINATION RELAY (TRAILER TOW) - BLACK 5 WAY CAV CIRCUIT FUNCTION 1 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER 1 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER 2 Z1 18BK/DG GROUND 3 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 4 L605 18DG RIGHT COMBINATION SIGNAL 5 - - RIGHT CYLINDER LOCK SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z462 20BK/WT GROUND 2 G162 20VT/WT RIGHT CYLINDER LOCK SWITCH MUX RIGHT DOOR SPEAKER - BLACK/RED 6 WAY CAV CIRCUIT FUNCTION 1 X154 20GY/YL (HIGH LINE) RIGHT FRONT INSTRUMENT PANEL SPEAKER (+) 2 X15 16GY/DG (HIGH LINE) AMPLIFIED SPEAKER GROUND 3 X156 20GY/LB (HIGH LINE) RIGHT FRONT INSTRUMENT PANEL SPEAKER (-) 4 X54 20GY RIGHT FRONT SPEAKER (+) 5 X13 16DG/GY (HIGH LINE) RADIO CHOKE OUTPUT 6 X56 20GY/BR RIGHT FRONT SPEAKER (-) RIGHT FOG LAMP (BUILT-UP-EXPORT) - WHITE 2 WAY CAV CIRCUIT FUNCTION 1 L90 18WT/OR FRONT FOG LAMP RELAY OUTPUT 2 Z348 18BK/OR GROUND 8W - 80 - 104 8W-80 CONNECTOR PIN-OUTS RS RIGHT FOG LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION A L90 18WT/OR FRONT FOG LAMP RELAY OUTPUT B Z348 18BK/OR GROUND RIGHT FRONT DOOR AJAR SWITCH (BASE) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G74 20VT/WT RIGHT FRONT DOOR AJAR SWITCH SENSE 2 Z74 20BK/WT GROUND RIGHT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G74 20VT/WT RIGHT FRONT DOOR AJAR SWITCH SENSE 2 Z74 20BK/WT GROUND 3 P4 20TN/BR RIGHT FRONT DOOR UNLOCK DRIVER 4 P2 20TN/GY RIGHT FRONT DOOR LOCK DRIVER RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L60 16WT/TN RIGHT FRONT TURN SIGNAL DRIVER 2 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT) 3 Z378 18BK/TN GROUND RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 105 RIGHT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q52 20OR RIGHT FULL OPEN SWITCH SENSE 2 Z76 20BK/YL GROUND RIGHT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L44 16WT/TN RIGHT LOW BEAM DRIVER 2 Z344 16BK/TN GROUND 3 L34 16WT/GY RIGHT HIGH BEAM DRIVER RIGHT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - WHITE 3 WAY CAV CIRCUIT FUNCTION 1 Z203 16BR GROUND 2 L78 16BK FUSED PARK LAMP RELAY OUTPUT (RIGHT) 3 L13 16RD HEADLAMP ADJUST SIGNAL RIGHT HIGH BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z344 16BR GROUND 1 Z344 16BR GROUND 2 L34 16GY RIGHT HIGH BEAM DRIVER RIGHT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X154 20GY/YL RIGHT FRONT I/P SPEAKER (+) 2 X156 20GY/LB RIGHT FRONT I/P SPEAKER (-) 8W - 80 - 106 8W-80 CONNECTOR PIN-OUTS RS RIGHT LIFTGATE FLOOD LAMP - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z312 20BK/YL GROUND 2 - - 3 M11 20YL/VT COURTESY LAMPS DRIVER RIGHT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z344 16BR GROUND 2 L44 16WT RIGHT LOW BEAM DRIVER RIGHT MID READING LAMP (PREMIUM/LUXURY) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 20YL/OR COURTESY LAMPS DRIVER 2 Z327 20BK/OR GROUND 3 M27 20YL/LB READING LAMPS DRIVER RIGHT PARK LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z344 16BR GROUND 2 L78 16BK FUSED PARK LAMP RELAY OUTPUT (RIGHT) RIGHT POWER MIRROR - BLACK 12 WAY CAV CIRCUIT FUNCTION 1 P174 20TN/LB (BUILT-UP-EXPORT) RIGHT FOLDING MIRROR UNFOLD DRIVER 2 - - 3 - - 4 P68 20TN/YL (MEMORY) RIGHT MIRROR HORIZONTAL POSITION SIGNAL 5 P66 20TN/LG (MEMORY) RIGHT MIRROR SENSOR GROUND 6 P67 20TN/OR (MEMORY) RIGHT MIRROR VERTICAL POSITION SIGNAL 7 P159 20TN/DG (BUILT-UP-EXPORT/ RHD) DRIVER FOLDING MIRROR FOLD DRIVER 7 P160 20TN/LG (BUILT-UP-EXPORT/ LHD) PASSENGER FOLDING MIRROR RELAY OUTPUT 8 Z216 20BK/DB GROUND 9 C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 10 P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN) 11 P72 20TN/GY RIGHT MIRROR UP DRIVER 12 P74 20TN/DB RIGHT MIRROR LEFT DRIVER RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 107 RIGHT REAR LAMP ASSEMBLY - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 L62 18WT/BR (EXCEPT BUILT-UP-EXPORT) RIGHT REAR TURN SIGNAL DRIVER 1 Z362 18BK/BR (BUILT-UP-EXPORT) GROUND 2 L62 18WT/BR (BUILT-UP-EXPORT) RIGHT REAR TURN SIGNAL DRIVER 3 L78 18WT/OR (EXCEPT BUILT-UP-EXPORT) FUSED PARK LAMP RELAY OUTPUT (RIGHT) 3 L50 18WT/TN (BUILT-UP-EXPORT) BRAKE LAMP SWITCH OUTPUT 4 L1 18WT/LG BACK-UP LAMP DRIVER 5 Z362 18BK/BR (EXCEPT BUILT-UP-EXPORT) GROUND 5 L38 20WT/YL (BUILT-UP-EXPORT) REAR FOG LAMP SWITCH OUTPUT 6 L50 18WT/TN (EXCEPT BUILT-UP-EXPORT) PRIMARY BRAKE SWITCH SIGNAL 6 L78 18WT/OR (BUILT-UP-EXPORT) FUSED PARK LAMP RELAY OUTPUT (RIGHT) RIGHT REAR PILLAR SPEAKER - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X158 20GY/YL RIGHT REAR PILLAR SPEAKER (+) 2 X152 20GY/WT RIGHT REAR PILLAR SPEAKER (-) RIGHT REAR READING LAMP (LUXURY) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 20YL/OR COURTESY LAMPS DRIVER 2 Z327 20BK/OR GROUND 3 M27 20YL/LB READING LAMPS DRIVER RIGHT REAR SPEAKER - BLACK/RED 6 WAY CAV CIRCUIT FUNCTION 1 X152 20GY/WT (HIGH LINE) RIGHT REAR PILLAR SPEAKER (-) 2 X15 16GY/DG (HIGH LINE) AMPLIFIED SPEAKER GROUND 3 X158 20GY/YL (HIGH LINE) RIGHT REAR PILLAR SPEAKER (+) 4 X52 20GY/DB RIGHT REAR SPEAKER (+) 5 X13 16DG/GY (HIGH LINE) RADIO CHOKE OUTPUT 6 X58 20GY/OR RIGHT REAR SPEAKER (-) RIGHT REAR VENT MOTOR - NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 - - 2 Q14 16OR/BR (LHD BUILT-UP-EXPORT) PASSENGER SIDE REAR WINDOW CLOSE 2 Q13 16OR/DB (RHD) DRIVER SIDE REAR WINDOW CLOSE 2 Q14 16OR/GY (LHD EXCEPT BUILT-UP-EXPORT) PASSENGER SIDE REAR WINDOW CLOSE 3 Q23 16OR/LB (RHD) DRIVER SIDE REAR WINDOW OPEN 3 Q24 16OR/DG (LHD) PASSENGER SIDE REAR WINDOW OPEN 8W - 80 - 108 8W-80 CONNECTOR PIN-OUTS RS RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X20 20RD/BK RADIO CONTROL MUX 2 X920 20RD/DB RADIO CONTROL MUX RETURN RIGHT REPEATER LAMP (BUILT-UP-EXPORT) - GRAY 2 WAY CAV CIRCUIT FUNCTION 1 A701 18BR/RD FUSED B(+) (HAZARD) 2 L162 20WT/VT RIGHT SIDE REPEATER LAMP FEED RIGHT SEAT AIRBAG - YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R32 18LB/OR (EXCEPT BUILT-UP-EXPORT) RIGHT SEAT SQUIB LINE 1 1 R34 18WT/BK (BUILT UP EXPORT) RIGHT SEAT SQUIB LINE 2 2 R34 18LB/WT (EXCEPT BUILT-UP-EXPORT) RIGHT SEAT SQUIB LINE 2 2 R32 18DG/WT (BUILT UP EXPORT) RIGHT SEAT SQUIB LINE 1 RIGHT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW/RED 7 WAY CAV CIRCUIT FUNCTION 1 R32 18LB/OR RIGHT SEAT SQUIB LINE 1 2 R34 18LB/WT RIGHT SEAT SQUIB LINE 2 3 - - 4 D25 20WT/VT PCI BUS 5 F214 18PK/LG FCM OUTPUT (SIACM RUN-START DRIVER) 6 - - 7 Z104 18BK/LG GROUND RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 109 RIGHT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER 2 Q68 16TN/BR RIGHT SLIDING DOOR OPEN DRIVER 3 Q70 16TN/OR RIGHT SLIDING DOOR CLOSE DRIVER 4 - - 5 A113 14WT/RD FUSED B(+) 6 - - 7 - - 8 Z124 14BK GROUND RIGHT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) - BLACK/RED 20 WAY CAV CIRCUIT FUNCTION 1 Q72 20TN/VT RIGHT DOOR MOTOR HALL EFFECT SUPPLY 2 - - 3 Q34 20OR/GY RIGHT DOOR LOCK SENSE 4 Q54 20OR/BR RIGHT DOOR IN/OUT HANDLE SWITCH SENSE 5 - - 6 - - 7 Q64 18OR/TN RIGHT DOOR MOTOR CLUTCH DRIVER 8 Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER 9 Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER 10 - - 11 D25 20WT/VT PCI BUS 12 G76 20TN/OR RIGHT SLIDING DOOR AJAR SWITCH SENSE 13 Q58 20OR/YL RIGHT PAWL SWITCH SENSE 14 Q52 20OR RIGHT FULL OPEN SWITCH SENSE 15 - GROUND-DRIVER SIDE IDENTIFIER (LHD/RHD) 16 Q56 20OR/VT RIGHT DOOR CHILD LOCKOUT SWITCH SENSE 17 Q74 20TN/YL RIGHT DOOR MOTOR HALL EFFECT SIGNAL 18 - - 19 G152 20VT/GY RIGHT SLIDING DOOR WAKE UP SIGNAL 20 Z26 20BK/TN GROUND RIGHT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 Z76 20BK/YL GROUND 2 Q58 20OR/YL RIGHT PAWL SWITCH SENSE 3 G76 20TN/OR RIGHT SLIDING DOOR AJAR SWITCH SENSE 4 Z76 20BK/YL GROUND 5 Q54 20OR/BR RIGHT DOOR IN/OUT HANDLE SWITCH SENSE 6 Q56 20OR/VT RIGHT DOOR CHILD LOCKOUT SWITCH SENSE 8W - 80 - 110 8W-80 CONNECTOR PIN-OUTS RS RIGHT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 P38 20TN/DB RIGHT SLIDING DOOR LOCK DRIVER 2 P34 20TN/LB RIGHT SLIDING DOOR UNLOCK DRIVER 3 Q34 20OR/GY RIGHT DOOR LOCK SENSE 4 Z76 20BK/YL GROUND RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 P38 20BK/DB RIGHT SLIDING DOOR LOCK DRIVER 2 P34 20BK/TN RIGHT SLIDING DOOR UNLOCK DRIVER 3 G76 20BK/DG RIGHT SLIDING DOOR AJAR SWITCH SENSE 4 Z76 20BK GROUND RIGHT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 - - 2 Q72 20TN/VT RIGHT DOOR MOTOR HALL EFFECT SUPPLY 3 Q68 16TN/BR RIGHT SLIDING DOOR OPEN DRIVER 4 Z164 18BK/TN GROUND 5 Q64 18OR/TN RIGHT DOOR MOTOR CLUTCH DRIVER 6 Q70 16TN/OR RIGHT SLIDING DOOR CLOSE DRIVER 7 Z34 20BK/TN GROUND 8 Q74 20TN/YL RIGHT DOOR MOTOR HALL EFFECT SIGNAL RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY CAV CIRCUIT FUNCTION A V37 20VT/TN (BUILT UP EXPORT) SPEED CONTROL SWITCH SIGNAL A V37 20DG/VT (EXCEPT BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL B Z23 20BK/VT RIGHT SPEED CONTROL SWITCH GROUND RIGHT STOP/TURN SIGNAL RELAY (TRAILER TOW) - BLACK 5 WAY CAV CIRCUIT FUNCTION 1 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 1 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 2 Z1 18BK/DG GROUND 2 Z1 18BK/DG GROUND 3 L74 18LG RIGHT STOP SIGNAL 4 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER 5 L605 18DG RIGHT COMBINATION SIGNAL RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 111 RIGHT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - ORANGE 2 WAY CAV CIRCUIT FUNCTION 1 Z344 16BR GROUND 2 L60 16YL RIGHT FRONT TURN SIGNAL DRIVER RIGHT VISOR/VANITY LAMP (PREMIUM/LUXURY) - BLACK 2 WAY CAV CIRCUIT FUNCTION A Z327 20BK/OR GROUND B M27 20YL/LB READING LAMPS DRIVER SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY CAV CIRCUIT FUNCTION 1 - - 2 D25 20WT/VT PCI BUS 3 - - 4 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 5 Z120 20BK/WT GROUND 6 A114 20GY/RD FUSED B(+) (I.O.D.) SIREN (UNITED KINGDOM) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 D97 18WT/OR SIREN SIGNAL OUTPUT 2 D96 18WT/LB SIREN SIGNAL CONTROL 3 A600 18RD/LB SIREN SUPPLY 4 G944 18LB/BR SIREN SIGNAL RETURN SOLENOID/PRESSURE SWITCH ASSY (EATX) - BLACK 8 WAY CAV CIRCUIT FUNCTION 1 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE 2 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE 3 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE 4 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT 5 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL 6 T60 18YL/GY OVERDRIVE SOLENOID CONTROL 7 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL 8 T19 18YL/DB 2-4 SOLENOID CONTROL 8W - 80 - 112 8W-80 CONNECTOR PIN-OUTS RS SPEED CONTROL SERVO (GAS) - BLACK 4 WAY CAV CIRCUIT FUNCTION 1 V36 18VT/YL SPEED CONTROL VACUUM SOLENOID CONTROL 2 V35 18VT/OR SPEED CONTROL VENT SOLENOID CONTROL 3 V30 18VT/WT SPEED CONTROL BRAKE SWITCH OUTPUT 4 Z155 18BK/LG GROUND THATCHAM ALARM MODULE C1 (UNITED KINGDOM) - BLACK 16 WAY CAV CIRCUIT FUNCTION 1 - - 2 - - 3 G22 20YL VTSS INDICATOR SUPPLY 4 D23 20WT/BR FLASH PROGRAM ENABLE 5 D97 20WT/OR SIREN SIGNAL OUTPUT 6 D96 20WT/LB SIREN SIGNAL CONTROL 7 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 8 G944 20LB/BR SIREN SIGNAL RETURN 9 - - 10 - - 11 G922 20GY VTSS INDICATOR DRIVER 12 - - 13 D25 20WT/VT PCI BUS 14 - - 15 L91 20WT/DB HAZARD SWITCH SENSE 16 A600 20RD/LB SIREN SUPPLY THATCHAM ALARM MODULE C2 (UNITED KINGDOM) - WHITE 4 WAY CAV CIRCUIT FUNCTION 1 18BK/LB REAR INTRUSION SENSOR SIGNAL 2 18BK/LB FRONT INTRUSION SENSOR SIGNAL 3 18BK/WT SENSOR GROUND 4 18BK/WT SENSOR GROUND THROTTLE POSITION SENSOR (GAS) - GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K900 18DB/DG SENSOR GROUND 2 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 113 TORQUE CONVERTER CLUTCH SOLENOID (ATX) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 - - 2 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 3 K54 18DB/WT TORQUE CONVERTER CLUTCH SOLENOID CONTROL TRACTION CONTROL SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B27 20DG/WT TRACTION CONTROL SWITCH SENSE 2 Z427 20BK/WT GROUND TRAILER TOW CONNECTOR (EXCEPT BUILT-UP-EXPORT) - 4 WAY CAV CIRCUIT FUNCTION 1 L74 18LG RIGHT STOP SIGNAL 2 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT) 3 Z1 18BK/DG GROUND 4 L73 18YL LEFT STOP SIGNAL 8W - 80 - 114 8W-80 CONNECTOR PIN-OUTS RS TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY CAV CIRCUIT FUNCTION 1 T1 18DG/LB TRS T1 SENSE 2 - - 3 T3 18DG/DB TRS T3 SENSE 4 - - 5 - - 6 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL 7 D21 18WT/BR SCI TRANSMIT 8 T751 18YL FUSED IGNITION SWITCH OUTPUT (START) 9 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE 10 T10 18DG/LG TORQUE MANAGEMENT REQUEST SENSE 11 F1 18PK/WT FCM OUTPUT (UNLOCK-RUN-START) 12 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL 13 T13 18DG/VT SPEED SENSOR GROUND 14 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL 15 T15 18YL/BR TRANSMISSION CONTROL RELAY CONTROL 16 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT 17 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT 18 - - 19 T19 18YL/DB 2-4 SOLENOID CONTROL 20 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL 21 - - 22 - - 23 - - 24 - - 25 - - 26 - - 27 - - 28 - - 29 - - 30 - - 31 - - 32 - - 33 - - 34 - - 35 - - 36 - - 37 - - 38 - - 39 - - 40 - - 41 T41 18DG/GY (3.3L/3.8L) TRS T41 SENSE 41 T41 18YL/DB (2.4L) TRS T41 SENSE 42 T42 18DG/YL TRS T42 SENSE 43 D25 18WT/VT PCI BUS 44 - - 45 - - 46 D16 18WT/OR SCI RECEIVE 47 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE 48 - - 49 - - 50 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE 51 K900 18DB/DG SENSOR GROUND 52 T52 18DG/WT INPUT SPEED SENSOR SIGNAL 53 Z132 16BK/YL GROUND 54 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 115 TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY CAV CIRCUIT FUNCTION 55 T55 18YL/VT (AUTOSTICK) AUTOSTICK/OVERDRIVE OFF MUX INPUT 56 A104 18YL/RD FUSED B(+) 57 Z133 16BK/LG GROUND 58 N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL 59 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL 60 T60 18YL/GY OVERDRIVE SOLENOID CONTROL TRANSMISSION RANGE SENSOR (EATX) - DK. GRAY 10 WAY CAV CIRCUIT FUNCTION 1 T2 18DG/WT TRS REVERSE SENSE 2 - - 3 T13 18DG/VT SPEED SENSOR GROUND 4 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL 5 T41 18YL/DB (2.4L) TRS T41 SENSE 5 T41 18DG/GY (3.3L/3.8L) TRS T41 SENSE 6 Z252 18BK/WT GROUND 7 T1 18DG/LB TRS T1 SENSE 8 T3 18DG/DB TRS T3 SENSE 9 T42 18DG/YL TRS T42 SENSE 10 T41 18YL/DB PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41) TXV SOLENOID (ATC) - 2 WAY CAV CIRCUIT FUNCTION 1 C200 18LB/DG TXV SOLENOID FEED 2 C51 18DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT VEHICLE SPEED SENSOR (MTX/ATX) - BLACK 3 WAY CAV CIRCUIT FUNCTION 1 F202 18PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START) 1 F888 18BR/PK (2.4L) 8 VOLT SUPPLY 2 K900 20DB/DG (DIESEL) SENSOR GROUND 2 K900 18DB/DG (2.4L) SENSOR GROUND 3 N7 20DB/OR (DIESEL) VEHICLE SPEED SENSOR SIGNAL 3 N7 18DB/OR (2.4L) VEHICLE SPEED SENSOR SIGNAL WASHER FLUID LEVEL SWITCH - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z401 18BK/TN (EXCEPT BUILT-UP-EXPORT) GROUND 1 Z401 20BK/TN (BUILT UP EXPORT) GROUND 2 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE 8W - 80 - 116 8W-80 CONNECTOR PIN-OUTS RS WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F853 20RD WATER IN FUEL SENSOR SIGNAL 2 K900 18RD SENSOR GROUND WIPER MODULE - DK. GRAY 4 WAY CAV CIRCUIT FUNCTION 1 W3 12BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT 2 W7 20BR/GY FRONT WIPER PARK SWITCH SENSE 3 W4 12BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT 4 Z103 14BK/WT GROUND 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS 8W - 91 - 1 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TABLE OF CONTENTS page CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION This section provides illustrations identifying connector, ground, and splice locations in the vehicle. Connector, ground, and splice indexes are provided. Use the wiring diagrams in each section for connector, ground, and splice identification. Refer to the appropriate index for the proper figure number. For items that are not shown in this section N/S is placed in the Fig. column. CONNECTORS CONNECTOR NAME/NUMBER COLOR LOCATION FIG. A/C Compressor Clutch LTGY Top of A/C Compressor 9, 10, 11, 13, 14 A/C-Heater Control C1 (MTC) BK/RD Rear of Control 15, 18, 20 A/C-Heater Control C2 (MTC) BK/BL Rear of Control 15, 18, 20 A/C Pressure Transducer GY At Throttle Body 9, 11, 12, 13 Accelerator Pedal Position Sensor (Diesel) BK At Accelerator Pedal 36 Airbag Control Module YL/RD Right Side of Instrument Panel 15, 19, 20 Ambient Temperature Sensor BK On Radiator Closure Panel 1 Above ATC Control N/S ATC Remote Sensor Automatic Day/Night Mirror BK At Mirror N/S Autostick Switch BK Rear of Switch 16, 17, 18 Auto Temperature Control C1 (ATC) WT Rear of Control N/S Auto Temperature Control C2 (ATC) BK Rear of Control N/S Rear of Control N/S Auto Temperature Control C3 (ATC) Back-Up Lamp Switch BK On Transmission 12 Battery Temperature Sensor (Diesel) BK At Battery N/S Blower Motor Resistor C1 (MTC) BK Right Side of HVAC N/S Right Side of HVAC N/S Blower Motor Resistor C2 (MTC) Body Control Module C1 BK Under Left Instrument Panel 35, 36 Body Control Module C2 BK/GN Under Left Instrument Panel 35, 36 Body Control Module C3 BK/WT Under Left Instrument Panel 35, 36 Body Control Module C4 BK/GY Under Left Instrument Panel 15, 16, 25 Body Control Module C5 BK Under Left Instrument Panel 15, 16, 25 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Boost Pressure Sensor (Diesel) BK Top Left of Engine N/S Brake Fuid Level Switch BK On Master Cylinder 6 Brake Lamp Switch BK At Top Of Brake Pedal 35, 36 Brake Transmission Shift Interlock Solenoid (EATX) BK Near Steering Column 15, 16, 17, 26 C100 BK Left Fender Shield 5 C101 LTGY Left Fender Shield 5 C102 (2.4L) BK Top Front of Engine 10 C102 (3.3/3.8L) BK At Fuel Rail 13 C103 (Diesel) BK Left Side Engine Compartment N/S C106 (BUX) BK Near Left Headlamp Leveling Motor N/S C107 (BUX) BK Near Right Headlamp Leveling Motor N/S C200 GY Left Side Instrument Panel 15, 16, 25, 35, 36 C201 YL Left Side Instrument Panel 15, 16, 25, 35, 36 C202 GY Right Side Instrument Panel A/C Heatrer Unit 15, 19, 24 C203 (United Kingdom) WT Right Side of Instrument Panel N/S C300 (LHD) BK Left Front Door Lower N/S C300 (RHD) BK Right Front Door Lower C301 LTGY Left Front Door Upper N/S C302 LTGY Right Front Door Upper 8, 33, 37 C303 (LHD) BK Right Front Door Lower 8, 37 C303 (RHD) BK Left Front Door Lower 33, 37 C304 YL Left Wire Track Seat to Body 27 C305 GY Left Wire Track Seat to Body 27 C306 YL Right Wire Track Seat to Body 28 C307 GY Right Wire Track Seat to Body 28 C308 BL Left Rear Sliding Door 34 C309 GN Right Rear Sliding Door 27, 28, 33 C310 BK At Front Console N/S C311 GY Rear A/C Switch N/S C312 GY At Dome Lamp 28, 33 C313 BK At Rear Console N/S C314 BK Left Side Liftgate 42 C315 BK Right Side Liftgate 42 C316 BK Wire Track to Sliding Door N/S C317 BK Right Sliding Door 27 C318 (Trailer Tow) BK Left Quarter N/S Left Side Liftgate N/S C319 (Except Built-up Export) C320 DKGY Driver Power Seat on Seat Harness N/S C321 DKGY Under Passenger Seat N/S C322 BK On Seat Harness to Body 27 C324 BK Left Sliding Door N/S RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C325 BK Right Sliding Door 27 C326 YL At Driver Side Airbag N/S C327 YL At Passenger Side Airbag N/S C329 (Diesel) BK Left Rear Engine Compartment N/S C330 (Diesel) LTGY Left Rear Engine Compartment N/S C331 (Diesel) BK Left Rear Engine Compartment N/S Cabin Heater Assist C1 (Diesel) BK Top of Engine 11, 12 Cabin Heater Assist C2 (Diesel) BK Top of Engine 11, 12 Camshaft Position Sensor (Gas) BK Rear of Cylinder Head Right Side of Engine N/S Camshaft Position Sensor (Diesel) BK Rear of Cylinder Head 11, 12 Behind CD Changer N/S CD Changer Center Dome Lamp GY At Lamp N/S Center High Mounted Stop Lamp BK At Lamp 42 Clockspring - C1 WT Steering Column 15, 16, 17, 18, 26 Clockspring - C2 YL Steering Column 15, 16, 17, 18, 26 Clockspring - C3 BK Steering Column N/S Clockspring - C4 BK Steering Column N/S Clockspring - C5 YL Steering Column N/S Clutch Pedal Interlock Switch (Diesel) RD At Switch/Driver Side 36 Clutch Pedal Upstop Switch (Diesel) BK At Switch/Driver Side 36 Controller Anti-Lock Brake BK Right Side of Engine Compartment 9, 10, 12, 13, 14 Crank Case Ventilation Heater (Diesel) BK Top of Cylinder Head 11 Crankshaft Position Sensor (Diesel) BK Rear of Engine 12 Crankshaft Position Sensor (Gas) BK Rear of Engine 9, 13 Data Link Connector WT Lower Instrument Panel Near Steering Column 35, 36 Diagnostic Junction Port BK Lower Instrument Panel Near Steering Column 35, 36 Dosing Pump BK Top of Engine N/S Driver Airbag C1 BN Steering Column N/S Driver Airbag C2 BK Steering Column N/S Driver Blend Actuator (ATC) GY On HVAC N/S Driver Blend Actuator (MTC) GY On HVAC N/S Driver Door Courtesy Lamp GY At Lamp N/S Driver Door Lock Switch BK At Switch N/S Driver Heated Seat Back GN At Seat N/S Driver Heated Seat Cushion BK At Seat N/S Driver Heated Seat Module C1 GY Driver Heated Seat N/S Driver Heated Seat Module C2 GY Driver Heated Seat Back N/S Driver Heated Seat Module C3 GN At Seat N/S 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Driver Power Seat Front Riser Motor RD At Seat N/S Driver Power Seat Horizontal Motor BK At Seat N/S Driver Power Seat Rear Riser Motor RD At Seat N/S Driver Power Seat Recliner Motor GN At Seat N/S Driver Power Seat Switch GN At Switch N/S Driver Power Window Motor RD At Motor N/S Driver Power Window Switch GN At Switch N/S Driver Power Window Switch (RHD) NAT At Switch N/S Driver Seatbelt Switch WT At Switch on Seat Harness N/S On Seat Harness N/S Driver Seatbelt Tensioner EGR Solenoid (Diesel) BK Above Transmission Right Side of Engine N/S EGR Solenoid GY Above Transmission Right Side of Engine 9, 10, 11, 13 Electric Wiper De-Icer-C1 WT Right Side Instrument Panel 15, 1923 Electric Wiper De-Icer-C2 WT Left Side Instrument Panel 15, 16, 22 Engine Control Module C1 (Diesel) BK Right Side of Engine 11 Engine Control Module C2 (Diesel) BK Right Side of Engine 11 Engine Coolant Temperature Sensor (Gas) BK On Cylinder Block N/S Engine Coolant Temperature Sensor (Diesel) BL On Cylinder Block 11 Engine Oil Pressure Sensor (Diesel) BK Rear of Engine 12 Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 9 Engine Oil Temperature Sensor (Diesel) BK Rear of Engine 12 EVAP/Purge Solenoid BK Right Motor Mount 9, 13 Evaporator Temperature Sensor BK Right Side of HVAC N/S Floor Console Lamp BK At Lamp N/S Floor Console Power Outlet RD At Front Console N/S Front Blower Module C1 (ATC) BK On HVAC N/S Front Blower Module C2 (ATC) BK On HVAC N/S Front Cigar Lighter RD/NAT Rear of Lighter 15, 18, 20 Front Reading Lamps/Switch BK At Switch N/S Front Washer Pump Motor BK Right Fender Well 3 Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S Fuel Injector No.1 BK At Fuel Injector N/S Fuel Injector No.1 (Diesel) BK At Fuel Injector 11 Fuel Injector No.2 BK At Fuel Injector N/S Fuel Injector No.2 (Diesel) BK At Fuel Injector 11 RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Fuel Injector No.3 BK At Fuel Injector N/S Fuel Injector No.3 (Diesel) BK At Fuel Injector 11 Fuel Injector No.4 BK At Fuel Injector N/S Fuel Injector No.4 (Diesel) BK At Fuel Injector 11 Fuel Injector No.5 BK At Fuel Injector N/S Fuel Injector No.6 BK At Fuel Injector N/S Fuel Pump Module LTGY Side of Fuel Tank N/S Fuel Pressure Sensor (Diesel) BK Top Left of Engine 11 Generator BK Rear of Generator 10, 11, 13, 14 Glove Box Lamp BL Rear of Glove Box 18, 24 Glow Plug Relay (Diesel) BK Near Battery N/S Halo Lamp WT Steering Column 15, 16, 17, 18, 26 Headlamp Switch BK Rear of Switch 15, 16, 25 At Motor N/S Left Frame Rail 5 Rear of Pump 11 Headlamp Washer Pump Motor High Note Horn BK High Pressure Fuel Pump (Diesel) Hood Ajar Switch BK Left Fender 6 Idle Air Control Motor (2.4L) BK On Throttle Body 9 Idle Air Control Motor (3.3/3.8L) BK On Throttle Body 13 Ignition Coil Pack 2.4L BK Top of Valve Cover 9, 10 Ignition Coil Pack 3.3L, 3.8L DKGY Top of Engine 14 Ignition Switch BK Rear of Switch at Steering Column 15, 16, 17, 18, 26 Inlet Air Temperature Sensor BK Top Left of Engine N/S Instrument Cluster BK Rear of Cluster 15, 16, 23 Instrument Panel Switch Bank BK Right Center of Instrument Panel 15, 18, 20 Instrument Panel Power Outlet NAT Center of Instrument Panel N/S Integrated Power Module C1 LTGN Left Fender Shield 7 Integrated Power Module C2 GN/BL Left Fender Shield 7 Integrated Power Module C3 (Diesel) YL/RD Left Fender Shield 7 Integrated Power Module C3 (Gas) NAT/RD Left Fender Shield 7 Integrated Power Module C4 BL Left Fender Shield 7 Integrated Power Module C5 BK Left Fender Shield 7 Integrated Power Module C6 NAT Left Fender Shield 7 Integrated Power Module C7 BK/RD Left Fender Shield 7 Integrated Power Module C8 OR Left Fender Shield 7 Integrated Power Module C9 BK Left Fender Shield 7 Knock Sensor GY Front of Cylinder Block N/S Leak Detection Pump LTGY At Pump 9, 10 14 Left B Pillar Switch GY Left B Pillar 34 Left Cinch/Release Motor GY Left Sliding Door N/S Left Combination Relay BK Left Rear Quarter Panel N/S 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Left Cylinder Lock Switch BK At Switch N/S Left Door Speaker BK At Speaker N/S Left Fog Lamp WT At Lamp N/S Left Front Door Ajar Switch BK At Switch N/S Left Front Door Lock Motor/Ajar Switch BK Left Door N/S Left Front Park/Turn Signal Lamp BK At Lamp 1, 5 Left Front Wheel Speed Sensor BK Left Fender Side Shield N/S Left Full Open Switch BK Left Sliding Door N/S Left Headlamp BK At Lamp 1, 5 Left Headlamp Leveling Motor WT At Motor N/S Left High Beam Lamp BK At Lamp N/S Left Instrument Panel Speaker BK At Speaker 15, 16, 22 Left Liftgate Flood Lamp GY At Lamp 42 Left Low Beam Lamp BK At Lamp N/S Left Mid Reading Lamp GY At Lamp N/S Left Park Lamp BK At Lamp N/S Left Power Mirror BK At Mirror 22 Left Rear Lamp Assembly BK At Lamp 40 Left Rear Reading Lamp GY At Lamp N/S Left Rear Speaker BK At Speaker 40 Left Rear Vent Motor NAT At Motor 39, 40 Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 40 Steering Wheel N/S Left Remote Radio Switch Left Repeater Lamp GY Left Front Fender 4 Left Seat Airbag YL Left Seat N/S Left Side Impact Airbag Control Module YL/RD Left B Pillar 34 Left Sliding Door Control Module C1 BK Left Sliding Door N/S Left Sliding Door Control Module C2 BK/RD Left Sliding Door N/S Left Sliding Door Latch Sensing Switch BK Left Sliding Door N/S Left Sliding Door Lock Motor BK Left Sliding Door N/S Left Sliding Door Lock Motor/Ajar Switch BK Left Sliding Door N/S Left Sliding Door Motor BK Left Sliding Door N/S Left Speed Control Switch WT Steering Wheel N/S Left Stop/Turn Signal Relay BK Left Quarter Panel N/S Left Turn Signal Lamp OR AT Lamp N/S Left Visor/Vanity Lamp BK At Lamp N/S License Lamp DKGY At Lamp 42 Lift Pump Motor BK Left Rear Engine Compartment N/S RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Liftgate Ajar Switch (Manual Release) BK At Latch 42 Liftgate Ajar Switch (Power Release) BK Lower Liftgate 42 Liftgate Cinch/Release Motor BL Liftgate N/S Liftgate Cylinder Lock Switch BK At Switch 42 Liftgate Left Pinch Sensor BK Left Side of Liftgate N/S Liftgate Right Pinch Sensor BK Right Side of Liftgate N/S Low Note Horn BK Left Frame Rail 5 Manifold Absolute Pressure Sensor BK On Intake 10 Mass Air Flow Sensor (Diesel) OR Top of Engine 11, 12 Memory Seat/Mirror Module C1 GY Under Driver Seat N/S Memory Seat/Mirror Module C2 GY Under Driver Seat N/S Memory Seat/Mirror Module C3 WT Under Driver Seat N/S Memory Seat/Mirror Module C4 GY Under Driver Seat N/S Memory Seat Front Vertical Motor RD Under Seat N/S Memory Seat Front Vertical Position Sensor BK Under Seat N/S Memory Seat Horizontal Motor BK Under Seat N/S Memory Seat Horizontal Position Sensor BK Under Seat N/S Memory Seat Rear Vertical Motor RD Under Seat N/S Memory Seat Rear Vertical Position Sensor BK Under Seat N/S Memory Seat Recliner Motor GN Under Seat N/S Memory Seat Recliner Position Sensor BK Under Seat N/S Memory Seat Switch BK At Switch Driver Door N/S Message Center WT Rear of Message Center 15, 16, 23 Mode Door Actuator GY Left Side of HVAC N/S Multi Function Switch BK At Steering Column 15, 16, 17, 18, 26 Output Speed Sensor GY Front of Transmission 14 Overhead Console BK Front of Console N/S Oxygen Sensor 1/1 Upstream BK Rear of Engine 9, 10, 14 Oxygen Sensor 1/2 Downstream BK Rear of Engine 9, 10, 14 Park/Neutral Positon Switch BK Front of Transmission 10 Passenger Airbag YL Passenger Side of Instrument Panel 15, 18, 19 24 On HVAC N/S At Lamp 37 Passenger Blend Door Actuator Passenger Door Courtesy Lamp BK Passenger Door Lock Switch BK At Switch 37 Passenger Folding Mirror Relay BL Right Kick Panel N/S Passenger Heated Seat Back GN At Seat N/S Passenger Heated Seat Cushion BK At Seat N/S Passenger Heated Seat Module C1 GY At Heated Seat N/S 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Passenger Heated Seat Module C2 GY At Heated Seat Back N/S Passenger Heated Seat Module C3 GN At Heated Seat N/S Passenger Power Seat Front Riser Motor RD Under Seat N/S Passenger Power Seat Horizontal Motor BK Under Seat N/S Passenger Power Seat Rear Riser Motor RD Under Seat N/S Passenger Power Seat Recliner Motor GN Under Seat N/S Passenger Power Seat Switch GN At Switch N/S Passenger Power Window Motor RD At Motor 37 Passenger Power Window Switch BK At Switch 37 Passenger Seatbelt Switch On Seat Harness N/S Passenger Seatbelt Tensioner On Seat Harness N/S Pedal Adjust Module At Module N/S Pedal Adjust Switch At Switch N/S Power Folding Mirror Switch BK Near Steering Column 26 Power Liftgate Module C1 BK Left Quarter 39, 40 Power Liftgate Module C2 BK/RD Left Quarter 39, 40 Power Liftgate Motor BK Left Quarter 40 Power Mirror Switch BK Rear of Switch 25 Power Outlet NAT Instrument Panel 15, 18, 20 Power Seat Circuit Breaker GY Under Seat N/S Powertrain Control Module C1 GY/BK LT Fender Side Shield N/S Powertrain Control Module C2 GY LT Fender Side Shield N/S Power Window Circuit Breaker GY Left Side Kick Panel 35 36 Radiator Fan No.1 BK Left Side At Motor 1 Radiator Fan No.1 (Diesel) GY Left Side At Motor 2 Radiator Fan No.2 BK Right Side At Motor 1 Radiator Fan No.2 (Diesel) GY Right Side At Motor N/S Radiator Fan Relay BK Top of Left Front Frame Rail 1 Radiator Fan Relay No. 1 (Diesel) BL Left Front Engine Compartment 2 Radiator Fan Relay No. 2 (Diesel) BL Left Front Engine Compartment 2 Radiator Fan Relay No. 3 (Diesel) BL Left Front Engine Compartment 2 Radio C1 GY Rear of Radio 15 Radio C2 BK Rear of Radio 15 Rear A/C-Heater Unit LT/GN Right Quarter Panel N/S Rear Automatic Temperature Control Switch (ATC) BK Rear of Switch 34 Rear Blower Front Control Switch BK Rear of Switch N/S Right Quarter N/S Rear Blower Motor Power Module C1 RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER LOCATION FIG. Rear Blower Motor Power Module C2 Right Quarter N/S Rear Blower Rear Control Switch C1 Overhead N/S Rear Blower Rear Control Switch C2 Overhead N/S Left Quarter Panel 40 Right Quarter N/S Rear Power Outlet COLOR RD Rear Temperature Motor Rear Washer Pump Motor BK Right Fender Well 3 Rear Wiper Motor GY At Motor 42 Recirculation Door Actuator GY Right Side of HVAC N/S Remote Keyless Entry Antenna (JAPAN) BK Right Upper Instrument Panel 23 Remote Keyless Entry Module BK/RD Top Left of I.P. 15, 16 Right B-Pillar Switch GY Right B Pillar 33 Right Cinch/Release Motor GY Rear of Sliding Door 38 Right Combination Relay BK Left Quarter Panel N/S Right Cylinder Lock Switch BK Right Front Door 37 Right Door Speaker BK/RD At Speaker N/S Right Fog Lamp WT At Lamp 3 Right Front Door Ajar Switch BK At B Pillar N/S Right Front Door Lock Motor/Ajar Switch BK Right Front Door 37 Right Front Park/Turn Signal Lamp BK At Lamp 1, 3 Right Front Wheel Speed Sensor GY Right Fender Side Shield 9, 12, 13 Right Full Open Switch BK Right Sliding Door 38 Right Headlamp BK At Lamp 1, 3 Right Headlamp Leveling Motor WT At Right Headlamp N/S Right High Beam Lamp BK At Right Headlamp N/S Right Instrument Panel Speaker BK At Speaker 15, 18, 19 Right Liftgate Flood Lamp BK At Lamp 42 Right Low Beam Lamp BK At Right Headlamp N/S Right Mid Reading Lamp GY At Lamp N/S Right Park Lamp BK AT Lamp N/S Right Power Mirror BK At Mirror 15, 19, 23 Right Rear Lamp Assembly BK At Lamp 41 Right Rear Pillar Speaker BK At Speaker 41 Right Rear Reading Lamp GY At Lamp N/S Right Rear Speaker BK/RD At Speaker 41 Right Rear Vent Motor NAT At Motor 41 Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 41 Right Remote Radio Switch BK At Steering Wheel N/S Right Repeater Lamp GY Right Front Fender 33 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Right Seat Airbag YL At Passenger Seat N/S Right Side Impact Airbag Control Module YL/RD Right B Pillar 33 Right Sliding Door Control Module C1 BK Rear of Door 38, 39 Right Sliding Door Control Module C2 BK/RD Rear of Door 38, 39 Right Sliding Door Latch Sensing Switch BK At Sliding Door 38 Right Sliding Door Lock Motor BK Rear of Door 38 Right Sliding Door Lock Motor/Ajar Switch BK At Latch N/S Right Sliding Door Motor BK At Sliding Door 38 Right Speed Control Switch BK At Steering Wheel N/S Right Stop/Turn Signal Relay BK LT Quarter Panel N/S Right Turn Signal Lamp OR At Lamp N/S Right Visor/Vanity Lamp BK At Lamp N/S Sentry Key Immobilizer Module BK At Steering Column 15, 16, 17, 18, 26 Siren (United Kingdom) BK Left Front Body N/S Solenoid/Pressure Switch Assembly (EATX) BK Side of Transmission N/S Speed Control Servo BK Near Controller Antilock Brake 14 Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel Near Speaker N/S Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel Near Speaker N/S Throttle Position Sensor GY On Throttle Body 9, 13 Torque Converter Clutch Solenoid BK Front of Transmission 10 Traction Control Switch BK Rear of Swtich 16, 17, 26 Trailer Tow Connector BK Left Quarter Panel N/S Transmission Control Module BK Top of Transmission 14 Transmission Range Sensor GY Top of Transmission 14 Vehicle Speed Sensor BK Rear of Transmission 9, 12 Washer Fluid Level Switch BK Bottom of Reservoir 3 Left Rear Engine Compartment N/S Left Side Cowl 6 Water in Fuel Sensor (Diesel) Wiper Module BK RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) GROUNDS GROUND NUMBER LOCATION FIG. G100 Body Ground Near Powertrain Control Module N/S G101 Above Starter 10 G102 Left Headlamp Area 1 G103 Above Starter 10 G200 Right Side of Instrument Panel 15, 19, 24 G201 Right Side of Instrument Panel 15, 19, 24 G202 Near Radio N/S G300 Left B Pillar 27 G301 Right B Pillar 28, 33 G302 Left Rear Quarter N/S G400 Liftgate Ground N/S SPLICES SPLICE NUMBER LOCATION FIG. S101 800mm from T/O for G102 1 S102 500mm from T/O for G102 1 S103 (2.5L) Between T/O for Battery Temperature Sensor and T/O for C102 11 S103 (3.3L/3.8L) Near T/O for C100 N/S S104 Near T/O for G102 1 S105 (3.3L/3.8L) Near T/O for Battery (+) N/S S106 (2.4L) 40mm from T/O for Torque Converter Clutch Solenoid 10 S106 (2.5L) Near T/O for Battery Temperature Sensor 11 S106 (3.3L/3.8L) Near T/O for G103 14 S107 (2.4L) In T/O for EGR Solenoid 10 S107 (2.5L) Between T/O for Engine Starter Motor and T/O for Engine Control Module C1 12 S107 (3.3L/3.8L) In T/O for EGR Solenoid 14 S108 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S S109 (3.3L/3.8L) Near T/O for Camshaft Position Sensor N/S S110 Near T/O to G102 N/S S111 (2.4L) Near T/O for C101 N/S S111 (2.5L) Near T/O for Battery (-) N/S S111 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S S112 Near T/O for Intelligent Power Module - C3 N/S S113 (2.4L) Near T/O for Park/Neutral Position Switch N/S S114 (3.3L/3.8L) In T/O to Transmission Control Module N/S S115 (3.3L/3.8L) In T/O to Transmission Control Module N/S S116 (2.4L) 180mm from T/O for Torque Converter Clutch Solenoid 10 S116 (2.5L) Near T/O for Mass Air Flow Sensor 12 S116 (3.3L/3.8L) Near T/O for Ignition Coil Pack 14 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S117 (2.4L) Neat T/O for G101 and G103 10 S117 (3.3L/3.8L) Near T/O for Output Speed Sensor 14 S118 (2.4L) Near T/O for Knock Sensor 10 S119 (2.5L) Near T/O for Engine Starter Motor 11 S120 (2.4L) Near T/O for Oxygen Sensors 9 S120 (3.3L/3.8L) Near T/O for Oxygen Sensors 14 S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 14 S122 (2.4L) In T/O to Engine Starter Motor 10 S122 (3.3L/3.8L) In T/O to Engine Starter Motor 14 S123 In T/O to Low Note Horn 5 S124 (2.4L) Near T/O for Fuel Injector No.2 N/S S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S S126 In Right Headlamp Leveling Assembly N/S S127 (2.5L) Near T/O for Engine Starter Motor N/S S128 (2.5L) Near T/O for Engine Starter Motor 11 S129 (2.5L) Near T/O for Battery (+) N/S S130 (2.5L) Near T/O for Battery (+) N/S S131 (3.3L/3.8L) Near T/O for Transmission Control Module N/S S132 (2.5L) Near T/O for Battery (+) N/S S133 (2.5L) Near T/O for Intelligent Power Module C3 N/S S134 Near T/O for Controller Antilock Brake N/S S135 (2.5L) Near T/O for Glow Plug No.2 11 S136 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S S137 (2.5L) Near T/O for A/C Compressor Clutch 11 S138 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S S139 (2.5L) Between T/O for Engine Starter Motor and T/O for Engine Control Module C1 12 S141 (2.4L) Near T/O for Powertrain Control Module N/S S141 (2.5L) Near /t/O for G100 N/S S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 14 S143 (2.5L) Near T/O for Engine Control Module C1 11 S143 (3.3L/3.8L) Near T/O for Intelligent Power Module - C3 N/S S144 (2.5L) Between T/O for Battery Temperature Sensor and T/O for C103 11 S145 (2.5L) Near T/O for Battery (+) N/S S148 (2.5L) Near T/O for Engine Starter Motor 11 S150 (2.5L) Between T/O for Battery Temperature Sensor and T/O for C103 N/S S151 (2.5L) Near T/O for Radiator Fan Relay No.1 2 S152 (2.5L) Near T/O for Left Fog Lamp N/S S157 (2.5L) Near T/O for Glow Plug No.1 11 RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S177 In Right Headlamp Wiring Assembly N/S S179 In Left Headlamp Wiring Assembly N/S S187 (2.5L) Near T/O for Engine Control Module C1 11 S188 (2.5L) Near T/O for Radiator Fan Relay No.1 2 S201 In T/O to Instrument Panel Speaker 15, 21 S202 Near T/O for Instrument Panel Switch Bank 15, 21 S203 Near T/O for Instrument Panel Switch Bank 15, 21 S204 Near T/O to Instrument Panel Speaker 15, 21 S205 Near T/O for C201 15 S206 Near T/O for Instrument Cluster 15 S207 In A/C Unit Assembly N/S S208 (RHD) Between T/O for Antenna Connector and T/O for Front Cigar Lighter 21 S209 (RHD) Between T/O for Front Cigar Lighter and T/O for Brake Transmission Shift Interlock Solenoid 21 S210 (RHD) Near T/O for C203 21 S211 In Steering Column Wiring Assembly N/S S212 In Steering Column Wiring Assembly N/S S302 In Floor Pan Track Wiring 31 S303 In T/O to Data Link Connector 31 S304 Near T/O for C307 32 S305 Near T/O for Memory Seat/Mirror Module - C2 N/S S306 In Floor Pan Track Wiring 32 S307 Near T/O for Memory Power Seat Switch N/S S308 In Floor Pan Track Wiring 31 S309 In Floor Pan Track Wiring 31 S310 Near T/O for C301 30 S311 In Floor Pan Track Wiring 29 S312 Near T/O for C320 N/S S313 Near T/O for Power Liftgate Module 40 S314 In Floor Pan Track Wiring 29 S315 In Floor Pan Track Wiring 29 S316 In Floor Pan Track Wiring 29 S317 Near T/O for C101 30 S318 Near T/O for Power Seat Circuit Breaker N/S S319 In Floor Pan Track Wiring 32 S320 Near T/O for C200 31 S321 In T/O to Data Link Connector 31 S322 Near T/O for C301 30 S323 In Floor Pan Track Wiring 31 S324 In Floor Pan Track Wiring 29 S325 In Floor Pan Track Wiring 29 S326 Near T/O for C101 30 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S327 Near Left Side Impact Airbag Module 31 S328 (RS) In Floor Pan Track Wiring 32 S329 Near T/O to Left Rear Pillar Speaker 40 S330 Near T/O for Power Liftgate Module 40 S331 Near T/O for Power Liftgate Motor 40 S332 In Floor Pan Track Wiring 29 S333 (RS) In Floor Pan Track Wiring 32 S334 Near T/O to G301 29 S335 Near T/O for Left Rear Reading Lamp N/S S336 Near T/O for Left Rear Reading Lamp 29 S337 Near T/O for Right Mid Reading Lamp N/S S338 Near T/O for Right Visor/Vanity Lamp N/S S339 Near T/O for C312 N/S S340 Near T/O for Passenger Power Window Switch 37 S342 (LHD) Near T/O for Passenger Power Window Motor 37 S343 (LHD) Near T/O for Driver Power Window Motor 37 S344 In T/O to Right Sliding Door Control Module C2 39 S345 Near T/O for Right Sliding Door Motor 39 S346 Near T/O for Driver Power Window Switch 37 S347 Near T/O for Right Sliding Door Lock Motor 39 S348 Near T/O for Left Sliding Door Lock Motor 39 S349 In T/O to Left Sliding Door Control Module - C2 39 S350 Near T/O for Left Sliding Door Motor 39 S351 Near T/O for Liftgate Cylinder Lock Switch 42 S352 Near T/O for Liftgate Cinch/Release Motor 42 S353 Near T/O for C318 40 S354 (RG) Near T/O for C301 31 S354 (RS) Near T/O for Driver Heated Seat Module N/S S355 Near T/O for Passenger Heated Seat Module N/S S356 (RG) In Floor Pan Track Wiring 31 S356 (RS) Near T/O for Passenger Heated Seat Back N/S S358 (RG) In T/O for Data Link Connector N/S S364 (RHD) Near T/O for Passenger Power Window Window 37 S365 (LHD) Near T/O for Driver Power Window Window 37 S366 In Passenger Power Heated Seat Wiring Assembly N/S S368 Near T/O for C101 30 S370 In T/O to Pedal Adjust Module N/S S371 In T/O to Power Window Switch N/S RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 Fig. 1 HEADLAMP CONNECTORS CONNECTOR/GROUND/SPLICE LOCATION (Continued) 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 2 LEFT FRONT ENGINE COMPARTMENT Fig. 3 WASHER PUMP CONNECTORS RS RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 4 LEFT REPEATER LAMP Fig. 5 LEFT FENDER SHIELD 8W - 91 - 17 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 6 LEFT SIDE ENGINE COMPARTMENT CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 7 INTEGRATED POWER MODULE 8W - 91 - 19 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 8 RIGHT FRONT WHEEL HOUSING CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 Fig. 9 2.4 LITER ENGINE CONNECTORS REAR CONNECTOR/GROUND/SPLICE LOCATION (Continued) 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 10 2.4 LITER ENGINE FRONT CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 Fig. 11 2.5 LITER DIESEL ENGINE FRONT CONNECTOR/GROUND/SPLICE LOCATION (Continued) 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 12 2.5 LITER DIESEL ENGINE REAR CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 Fig. 13 3.3-3.8 LITER ENGINE REAR CONNECTOR/GROUND/SPLICE LOCATION (Continued) 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 14 3.3-3.8 LITER ENGINE FRONT CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 Fig. 15 INSTRUMENT PANEL HARNESS LHD CONNECTOR/GROUND/SPLICE LOCATION (Continued) 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 16 LEFT SIDE INSTRUMENT PANEL LHD CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 17 STEERING COLUMN 8W - 91 - 29 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 18 CENTER INSTRUMENT PANEL CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 19 RIGHT SIDE INSTRUMENT PANEL 8W - 91 - 31 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 20 CENTER INSTRUMENT PANEL RHD CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 21 INSTRUMENT PANEL RHD Fig. 22 LEFT SIDE INSTRUMENT PANEL UPPER RHD 8W - 91 - 33 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 23 RIGHT SIDE INSTRUMENT PANEL UPPER RHD Fig. 24 LEFT SIDE INSTRUMENT PANEL LOWER RHD RS RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 25 RIGHT SIDE INSTRUMENT PANEL LOWER RHD Fig. 26 STEERING COLUMN CONNECTORS RHD 8W - 91 - 35 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 27 LEFT SIDE BODY LHD CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 28 RIGHT SIDE BODY RHD 8W - 91 - 37 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 29 BODY HARNESS SPLICES CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 30 BODY HARNESS SPLICES Fig. 31 LEFT FRONT BODY SPLICES 8W - 91 - 39 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 32 REAR BODY SPLICES CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 33 RIGHT B PILLAR Fig. 34 LEFT B PILLAR 8W - 91 - 41 8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 35 LEFT SIDE KICK PANEL LHD CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43 Fig. 36 RIGHT SIDE KICK PANEL RHD CONNECTOR/GROUND/SPLICE LOCATION (Continued) 8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 37 PASSENGER DOOR Fig. 38 RIGHT SLIDING DOOR RS RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 45 Fig. 39 LIFTGATE AND SLIDING DOOR MODULES CONNECTOR/GROUND/SPLICE LOCATION (Continued) 8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 40 LEFT REAR BODY CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 41 RIGHT QUARTER 8W - 91 - 47 8W - 91 - 48 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS Fig. 42 LIFTGATE CONNECTOR/GROUND/SPLICE LOCATION (Continued) RS 8W-97 POWER DISTRIBUTION SYSTEM 8W - 97 - 1 8W-97 POWER DISTRIBUTION SYSTEM TABLE OF CONTENTS page POWER DISTRIBUTION SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS POWER DISTRIBUTION SYSTEMS . . . ACCESSORY RELAY DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS & TESTING - ACCESSORY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL ....................... INSTALLATION . . . . . . . . . . . . . . . . . . . . INTEGRATED POWER MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......1 ......1 ......2 ......2 ......2 ......2 ......3 ......3 ......3 POWER DISTRIBUTION SYSTEM DESCRIPTION This group covers the various standard and optional power distribution components used on this model. The power distribution system for this vehicle consists of the following components: • Integrated Power Module (IPM) • Front Control Module (FCM) • Power Outlets Refer to Wiring Diagrams for complete circuit schematics. The power distribution system also incorporates various types of circuit control and protection features, including: • Automatic resetting circuit breakers • Blade-type fuses • Bus bars • Cartridge fuses • Circuit splice blocks • Flashers • Fusible links • Relays Following are general descriptions of the major components in the power distribution system. See the owner’s manual in the vehicle glove box for more information on the features and use of all of the power distribution system components. page OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL .......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . IOD FUSE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL .......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . POWER OUTLET DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS & TESTING - POWER OUTLET REMOVAL .......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...3 ...4 ...4 . . . . . . . . .4 .5 .5 .5 ...5 ...5 ..5 ...6 ...6 OPERATION The power distribution system for this vehicle is designed to provide safe, reliable, and centralized distribution points for the electrical current required to operate all of the many standard and optional factory-installed electrical and electronic powertrain, chassis, safety, security, comfort and convenience systems. At the same time, the power distribution system was designed to provide ready access to these electrical distribution points for the vehicle technician to use when conducting diagnosis and repair of faulty circuits. The power distribution system can also prove useful for the sourcing of additional electrical circuits that may be required to provide the electrical current needed to operate many accessories that the vehicle owner may choose to have installed in the aftermarket. 8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEM RS POWER DISTRIBUTION SYSTEM (Continued) SPECIAL TOOLS DIAGNOSIS AND TESTING POWER DISTRIBUTION SYSTEMS DIAGNOSIS & TESTING - ACCESSORY RELAY Terminal Pick Kit 6680 ACCESSORY RELAY DESCRIPTION The accessory relay is an electromechanical device that switches fused battery current to the accessory powered vehicle circuits when the ignition switch is turned to the Accessory or On positions. The delay feature will maintain power to the accessories for 45 seconds after the ignition is shut off or until a door is opened. This allows sufficient time to close windows and park the windshield wipers. The accessory relay is located in the Integrated Power Module (IPM) in the engine compartment. The accessory relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The accessory relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. OPERATION The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. The accessory relay (Fig. 1) is located in the Integrated Power Module (IPM), in the engine compartment. For complete circuit diagrams, refer to Wiring Diagrams. (1) Remove the accessory relay from the IPM. Refer to Accessory Relay in the Removal and Installation section of this group for the procedure. (2) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. (3) Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. (4) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay. Fig. 1 Accessory Relay DIAGNOSIS & TESTING - RELAY CIRCUIT TEST (1) The relay common feed terminal cavity (30) of the IPM is connected to battery voltage and should be hot at all times. Check for battery voltage at the fused B(+) circuit cavity in the IPM receptacle for the accessory relay. If OK, go to Step 2. If not OK, repair the fused B(+) circuit to the IPM fuse as required. (2) The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. (3) The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the fused B(+) fuse in the IPM that feeds the accessories when the relay is energized by the ignition switch. There should be continuity between the IPM cavity for relay terminal 87 and the fused B(+) fuse in the IPM at all times. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. RS 8W-97 POWER DISTRIBUTION SYSTEM 8W - 97 - 3 ACCESSORY RELAY (Continued) (4) The coil ground terminal (85) is connected to the electromagnet in the relay. It receives battery feed to energize the accessory relay when the ignition switch is in the Accessory or On positions. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (acc/run) circuit cavity for relay terminal 85 in the IPM receptacle for the accessory relay. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (acc/run) circuit to the ignition switch as required. (5) The coil battery terminal (86) is connected to the electromagnet in the relay. The IPM cavity for this terminal should have continuity to ground at all times. If not OK, repair the open ground circuit to ground as required. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the Integrated Power Module (IPM) cover from the IPM. (3) Remove the accessory relay from the IPM. Refer to the IPM cover for relay location. INSTALLATION (1) Position the accessory relay in the proper receptacle in the Integrated Power Module (IPM). (2) Push in firmly on the accessory relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. (3) Install the IPM cover. (4) Reconnect the battery negative cable. INTEGRATED POWER MODULE DESCRIPTION The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery on this model (Fig. 2). The power distribution center mates directly with the Front Control Module (FCM) to form the IPM Fuse and Relay Center. The power distribution center (PDC) is a printed circuit board based module that contains fuses and relays, while the front control module contains the electronics controlling the IPM and other functions. This IPM connects directly to the battery positive via a four pin connector. The ground connection is via two other connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by squeezing the two marked cover Fig. 2 BATTERY THERMAL GUARD 1 - BATTERY THERMAL GUARD 2 - INTEGRATED POWER MODULE 3 - FRONT CONTROL MODULE latches and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place by an IPM mounting bracket. This mounting bracket is designed to allow the IPM to rotate counter-clockwise once the locking tab is disengaged. The IPM mounting bracket is secured in place by bolts threaded into the left front wheel house. Replaceable components of the IPM assembly are broken down into the following components: the Power Distribution Center (PDC) (without fuses or relays), the IPM cover, the Front Control Module (FCM), the IPM mounting bracket, IPM bracket retaining clips and the IPM assembly which includes the power distribution center, the cover and FCM. Refer to the Front Control Module in the Electronic Control Module section of this service manual for information on the FCM. OPERATION All of the current from the battery and the generator output enters the Integrated Power Module (IPM) via a four- pin connector on the bottom of the module. The IPM cover is unlatched and opened or removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Refer to the Wiring sec- 8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEM RS INTEGRATED POWER MODULE (Continued) tion of the service manual for complete IPM circuit schematics. REMOVAL (1) Disconnect the negative and positive battery cables. (2) Remove the battery thermal guard from the vehicle. Refer to the Battery section for the procedure. (3) Remove the battery from the vehicle. Refer to the Battery section for the procedure. (4) Using a flat-bladed screwdriver, twist the Integrated Power Module (IPM) bracket retaining latch outward to free the intelligent power module from its mounting bracket (Fig. 3). Fig. 4 DISCONNECTING IPM 1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER Fig. 3 RELEASING INTEGRATED POWER MODULE FROM ITS MOUNTING BRACKET (5) Rotate the IPM counter-clockwise to access and disconnect the various electrical connectors (Fig. 4). (6) Free the IPM from its mounting bracket by removing the IPM bracket clips from the hinge. A screwdriver slipped up from under the hinge will free the clips. INSTALLATION (1) Snap the left side of the Integrated Power Module (IPM) housing in its mounting bracket and connect the various electrical connectors. Care must be taken that the Connector Positive Assurance (CPA) on the five-pin B+ connector is positively engaged to prevent generating a Diagnostic Trouble Code (DTC). NOTE: IPM electrical connectors are color coded to ease location reference. (2) Being certain no wires are stressed or pinched, rotate the IPM clock-wise until secured in mounting bracket. An audible click may be heard. (3) Install the battery in the vehicle. Refer to the Battery section for the procedure. (4) Install the battery thermal guard in the vehicle. Refer to the Battery section for the procedure. (5) Connect the negative and positive battery cables. (6) Using a diagnostic scan tool, check for any stored diagnostic trouble codes and correct, check that all vehicle options are operational before returning the vehicle to service. IOD FUSE DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed from its normal cavity in the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to remove the IOD fuse from the storage location and install it into the IPM fuse cavity marked IOD as part of the preparation procedures performed just prior to new vehicle delivery. The IPM has a molded plastic cover that can be removed to provide service access to all of the fuses and relays in the IPM. An integral latch and hinges are molded into the IPM cover for easy removal. A fuse layout map is integral to the underside of the IPM cover to ensure proper fuse and relay identifica- RS 8W-97 POWER DISTRIBUTION SYSTEM 8W - 97 - 5 IOD FUSE (Continued) tion. The IOD fuse is a 15 ampere blade-type cartridge fuse and, when removed, it is stored in a fuse cavity adjacent to the washer fuse within the IPM. 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 removed 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 removed from the IPM fuse cavity when the vehicle is shipped from the assembly plant. Dealer personnel must install 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 removing 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. Refer to Battery System for additional service information. REMOVAL (1) Turn the ignition switch to the Off position. (2) Unlatch and open the cover of the intelligent power module. (3) Remove the IOD fuse from fuse location marked IOD of the Integrated Power Module (IPM). (4) Store the removed IOD fuse by installing it in the unused fuse storage marked SPARE of the IPM. (5) Close and latch the IPM. INSTALLATION (1) Be certain the ignition switch is in the Off position. (2) Unlatch and open the cover of the Integrated Power Module (IPM). (3) Remove the stored 15 amp IOD fuse from fuse storage marked SPARE of the IPM. (4) Use a thumb to press the IOD fuse firmly down into IPM fuse cavity marked IOD. (5) Close and latch the IPM cover. POWER OUTLET DESCRIPTION Accessory power outlets are standard equipment on this model. Two power outlets are installed in the instrument panel center lower bezel, which is located near the bottom of the instrument panel center stack area. Two additional power outlets are also incorporated into the vehicle, one on the left rear C-pillar trim and the other in the center console, if equipped. The power outlets bases are secured by a snap fit in the appropriate bezels. A hinged plug flips closed to conceal and protect the power outlet base when the power outlet is not being used. The power outlet receptacle unit and the power outlet plugs are each available for service replacement. OPERATION 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 on the instrument panel marked with a battery receives battery voltage from a fuse in the Integrated Power Module (IPM) at all times. The other power outlet on the instrument panel marked with a key receives battery voltage only when the key is in the on position. The power outlet located in the center console receives battery voltage all the time when positioned between the front seats and key-on voltage when positioned between the rear seats. The power outlet located on the C-pillar receives battery voltage only when the key is in the on position. DIAGNOSIS AND TESTING DIAGNOSIS & TESTING - POWER OUTLET For complete circuit diagrams, refer to Cigar Lighter/Power Outlet in Wiring Diagrams. 8W - 97 - 6 8W-97 POWER DISTRIBUTION SYSTEM RS POWER OUTLET (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. (1) Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. (2) Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. (3) Open the power outlet door. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. (4) Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. (5) Disconnect and isolate the battery negative cable. Remove the appropriate bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. (6) Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Fig. 5 Outlet Base Removal 1 2 3 4 - RETAINING BOSSES-ENGAGE PLIERS HERE PARTIALLY REMOVED EXTERNAL SNAP-RING PLIERS PULL BASE OUT-THROUGH MOUNTING RING REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Look inside and note position of the retaining bosses (Fig. 5). (3) Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. (4) Pull out the base through mounting ring by gently rocking pliers. A tool can be made to do the same. Refer to (Fig. 6). (5) Disconnect the base wires. (6) Set base aside. Remove light ring and disconnect wire. INSTALLATION (1) Position the mounting ring on the instrument panel and feed the wires through the ring. Index the cap and the mounting ring with the index tab at the Fig. 6 Tool For Outlet Removal 1 2 3 4 - 2.5MM (3/32 INS.) WELD 100MM (4 INS.) 22.25 TO 22.45MM (7/8 TO 57/64 INS.) 9 o’clock position to the key in the instrument panel. Install the ring. (2) Connect the wires to the base. Orientate the base alignment rib at the 11 o’clock position to mate the groove in the mounting ring to the base. (3) Push the base into the bezel until it locks in place. (4) Check operation of outlet or element and install the 12 volt outlet cap. ELECTRONIC CONTROL MODULES RS 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page ELECTRONIC CONTROL MODULES STANDARD PROCEDURE - PCM/SKIM PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTABLE PEDAL MODULE DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL MODULE . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL .............................3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BODY CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL .............................5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CONTROLLER ANTILOCK BRAKE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL .............................6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DATA LINK CONNECTOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FRONT CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DIAGNOSIS AND TESTING - FRONT CONTROL MODULE . . . . . . . . . . . . . . . . . . . . 8 REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HEATED SEAT MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING - HEATED SEAT MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 POWER LIFTGATE MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 POWERTRAIN CONTROL MODULE DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 11 page DIAGNOSTIC TROUBLE CODE . . . . . . . . OPERATION - SENSOR RETURN - PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION - SCI RECEIVE - PCM INPUT OPERATION - IGNITION SENSE - PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION - PCM GROUND . . . . . . . . . OPERATION OPERATION - 8-VOLT SUPPLY - PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION - 5 VOLT SUPPLY - PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - OBTAINING DIAGNOSTIC TROUBLE CODES . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . SENTRY KEY IMMOBILIZER MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE - PINION FACTOR SETTING . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - QUICK LEARN PROCEDURE . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . MEMORY SEAT/MIRROR MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - MEMORY SEAT/MIRROR MODULE . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . SLIDING DOOR CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . 25 . . 25 . . . 25 . . . 25 . . . 25 . . . 25 . . . 25 . . . 26 . . . 26 . . . . . . . . . 26 . 27 . 27 . 27 . . . 28 . . . 28 . . . 31 . . . 31 . . . 31 . . . 32 . . . 33 . . . 33 . . . 33 . . . 33 . . . 33 . . . . . . . . . 33 . 34 . 34 . 34 8E - 2 ELECTRONIC CONTROL MODULES ELECTRONIC CONTROL MODULES STANDARD PROCEDURE - PCM/SKIM PROGRAMMING NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM (SBEC) and the SKIM are replaced at the same time perform the following steps in order: (1) Program the new PCM (SBEC) (2) Program the new SKIM (3) Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. (1) Turn the ignition switch on (transmission in park/neutral). (2) Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. (3) Select PCM REPLACED (GAS ENGINE). (4) Enter secured access mode by entering the vehicle four-digit PIN. (5) Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured 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. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). (6) Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). (7) Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. RS (8) The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading. Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM (1) Turn the ignition switch on (transmission in park/neutral). (2) Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. (3) Select PCM REPLACED (GAS ENGINE). (4) Program the vehicle four-digit PIN into SKIM. (5) Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. (6) Select YES to update VIN (the SKIM will learn the VIN from the PCM). (7) Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). (8) Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM (1) Turn the ignition switch on park/neutral). (2) Use the DRB III and select SKIM then MISCELLANEOUS. (3) Select PROGRAM IGNITION (4) Enter secured access mode vehicle four-digit PIN. (transmission in THEFT ALARM, KEY’S. by entering the NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: • faulty ignition key transponder • ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done SKIM transponder ID memory is full. ELECTRONIC CONTROL MODULES RS 8E - 3 ELECTRONIC CONTROL MODULES (Continued) (5) Obtain ignition keys to be programmed from customer (8 keys maximum). (6) Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS. (7) Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. ADJUSTABLE PEDAL MODULE DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL MODULE Refer to Appropriate Diagnostic Information. REMOVAL (1) Remove adjustable pedal assembly from vehicle. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/PEDAL - REMOVAL) (2) Disconnect 2 wiring connectors from module (Fig. 1). (4) Install adjustable pedal assembly. (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/PEDAL INSTALLATION) BODY CONTROL MODULE DESCRIPTION The Body Control Module (BCM) is located in the passenger compartment, attached to the bulkhead underneath the left side of the instrument panel. The BCM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the BCM 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 PCI data bus. OPERATION Fig. 1 Adjustable Pedal Module 1 2 3 4 - CABLE - ADJUSTABLE PEDAL MODULE - WIRING CONNECTORS - ADJUSTABLE PEDAL ASSEMBLY (3) (Fig. (4) (5) Remove cable from routing clips on module 1). Remove module mounting screws. Remove module. INSTALLATION (1) Install module on pedal assembly and install mounting screws. (2) Place cable in routing clips on module (Fig. 1). (3) Connect 2 wiring connectors to module (Fig. 1). The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the BCM is interfaced to the vehicle’s serial bus communications network, referred to as the Programmable Communications Interface (PCI) bus. This network consists of the; • Powertrain Control Module (PCM) • Transmission Control Module (TCM) • Mechanical Instrument Cluster (MIC) • Occupant Restraint Controller (ORC) • Compass/Mini-Trip Computer (CMTC) • Electronic Vehicle Information Center (EVIC) • Controller Antilock Brake (CAB) • HVAC Control Module • Sliding Door Control Modules (driver and passenger side doors) • Power Liftgate Module (PLG) • Audio system equipped with RAZ, RBU, RBK, and RBB radios. • Side Impact Airbag Control Module (SIACM) • Memory Seat Module (MSM) • Sentry Key Immobilizer Module (SKIM) The BCM is operational when battery power is supplied to the module. The BCM provides the following features: • Power Door Locks • Automatic Door Locks • Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes, and all 8E - 4 ELECTRONIC CONTROL MODULES RS BODY CONTROL MODULE (Continued) interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. • Chime Driver • Compass/Mini-Trip support. • Interior Lighting (Courtesy/Reading Lamps) • BCM Diagnostic Reporting • Electronic Liftgate Release (with Power Door Locks) • Exterior Lighting • Headlamp Time Delay (with/without Automatic Headlamps) • Illuminated Entry • Fade to Off Interior Lamps - This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. • Pulse Width Modulated Instrument Panel Dimming • Door Lock Inhibit - This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the Remote Keyless Entry (RKE) lock/unlock button under these conditions result in normal lock/unlock activation. The BCM has the ability to LEARN additional features in the vehicle, provided the appropriate switch input and PCI data bus messages are received. Refer to the LEARNED FEATURES table. LEARNED FEATURES FEATURE LEARNING KEY CENTRAL LOCKING (WITH VTSS ONLY) DRIVER/PASSENGER KEY CYLINDER SWITCH PRESENT AUTOMATIC HEADLAMPS PCI MESSAGE FROM OVERHEAD OR HEADLAMP SWITCH POSITION (AUTO) REMOTE KEYLESS ENTRY RKE MESSAGE RECEIVED FROM MODULE FRONT FOG LAMPS HEADLAMP SWITCH POSITION (PARK W/FRONT FOG LAMPS) POWER SLIDING DOOR PCI IFR RECEIVED FROM MODULE THE BCM HAS FOUR SWITCH INPUTS FOR THE POWER SLIDING DOOR FEATURE; LOCATED IN THE OVERHEAD CONSOLE ARE THE LEFT AND RIGHT SIDE SLIDING DOOR SWITCHES TO ACTIVATE EITHER OR BOTH SLIDING DOORS UNDER THE PROPER CONDITIONS. ALSO ARE B-PILLAR SWITCHES LOCATED ON THE LEFT AND RIGHT B-PILLAR POSTS. POWER LIFTGATE PCI IFR RECEIVED FROM MODULE THE BCM HAS ONE LIFTGATE INPUT LOCATED IN THE OVERHEAD CONSOLE. POWER LOCKOUT SWITCH INPUT THE BCM HAS ONE LOCKOUT SWITCH INPUT THAT WHEN ENABLED WILL DISABLE THE B-PILLAR SLIDING DOOR SWITCHES FROM ACTIVATING EITHER SLIDING DOOR WHEN DEPRESSED. PCI AUDIO SYSTEM PCI MESSAGE RECEIVED FROM MODULE NOTE: SWAPPING OUT A HIGHLINE RADIO FOR A NON-PCI BUS RADIO (RAS) WILL RESULT IN IMPROPER HARDWIRE COMMUNICATION BETWEEN THE BCM AND THE NEW RAS RADIO. THE LCD DISPLAY WILL NOT ILLUMINATE PROPERLY DUE TO THE BCM LEARNING THAT A PCI RADIO EXISTS. HOWEVER, THE BCM CAN RE-INITIALIZE LEARNED FEATURES VIA THE USE OF THE DRB IIIT SCAN TOOL. REMOTE RADIO CONTROLS REMOTE RADIO SWITCHES PRESENT VEHICLE THEFT SECURITY DRIVER/PASSENGER DOOR CYLINDER LOCK SWITCH MEMORY SEAT AND MIRRORS MEMORY SEAT SWITCH PRESENT AND OR PCI MESSAGE RECEIVED FROM MEMORY MODULE ABS W/TRACTION CONTROL PCI MESSAGE RECEIVED FROM CAB SENTRY KEY IMMOBILIZER SYSTEM PCI MESSAGE RECEIVED FROM SKIM OR VTSS PRESENT ADJUSTABLE PEDAL MODULE PCI MESSAGE RECEIVED FROM ADJUSTABLE PEDAL MODULE (APM) ELECTRONIC CONTROL MODULES RS 8E - 5 BODY CONTROL MODULE (Continued) When replacing a BCM there are three modules available: • Base • Midline • Highline The Midline controller is used on vehicles that have Power Door Locks and the Highline controller is used for vehicles equipped with a Power Liftgate. If a vehicle is equipped with the Vehicle Theft Security System, the Midline/Highline controller becomes a Premium when the theft feature is enabled. CAUTION: Do not swap Body Control Modules between vehicles or body controller’s off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system error. When an OPEN or a SHORT circuit exists, the diagnostic tool can be used to read the BCM faults. The faults are very descriptive in identifying the appropriate feature that has faulted. The only two faults that the BCM logs that conclude the replacement of a BCM are faults; • # 01 - Internal BCM failure (replace BCM) • # 1F - J1850 Internal Hardware Failure (replace BCM) Otherwise the appropriate diagnostic procedures for each of the features should be taken when the BCM logs a fault. CONTROLLER ANTILOCK BRAKE DESCRIPTION The controller antilock brake (CAB) 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. The CAB is mounted to the HCU as part of the integrated control unit (ICU) (Fig. 2). The CAB uses a 24-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the lower instrument panel silencer. (3) Remove the knee blocker and reinforcement (Refer to 23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER REINFORCEMENT - REMOVAL). (4) Disconnect the five wire connectors from the bottom of the Body Control Module (BCM). (5) Move bulkhead wiring aside. (6) Remove the screws holding the BCM to the bulkhead. (7) Remove the BCM from the mounting bracket. INSTALLATION (1) Install the BCM to the mounting bracket. (2) Install the screws holding the BCM to the bulkhead. (3) Connect the five wire connectors to the bottom of the Body Control Module (BCM). (4) Install the knee blocker and reinforcement (Refer to 23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER REINFORCEMENT - INSTALLATION). (5) Install the lower instrument panel silencer. (6) Connect the battery negative cable. (7) Verify proper operation of BCM and its functions. Fig. 2 Integrated Control Unit (ICU) 1 2 3 4 - PUMP/MOTOR HCU PUMP/MOTOR CONNECTOR CAB OPERATION The primary functions of the controller antilock brake (CAB) are to: • Monitor the antilock brake system 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 an ABS mode. • Store diagnostic information. • Provide communication to the DRBIIIt scan tool while in diagnostic mode. • Illuminate the amber ABS warning indicator lamp. • (With traction control only) Illuminate the TRAC ON lamp in the message center on the instrument panel when a traction control event occurs. 8E - 6 ELECTRONIC CONTROL MODULES RS CONTROLLER ANTILOCK BRAKE (Continued) • (with traction control only) Illuminate the TRAC OFF lamp when the amber ABS warning indicator lamp illuminates. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. (2) Remove the battery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL). (3) Disconnect the vacuum hose connector at the tank built into the battery tray. (4) Remove the screw securing the coolant filler neck to the battery tray. (5) Remove the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - REMOVAL). (6) Pull up on the CAB connector lock and disconnect the 24–way electrical connector (Fig. 3). NOTE: If the vehicle is equipped with traction control, the TRAC OFF lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The CAB 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 CAB commands the CAB command 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 CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. These DTC’s will remain in the CAB memory even after the ignition has been turned off. The DTC’s can be read and cleared from the CAB memory by a technician using the DRBIIIt scan tool. If not cleared with a DRBIIIt scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles. CAB INPUTS • • • • • • • Wheel speed sensors (four) Brake lamp switch Ignition switch System and pump voltage Ground Traction control switch (if equipped) Diagnostic communication (PCI) CAB OUTPUTS • (via • • • Amber ABS warning indicator lamp actuation BUS) Instrument cluster (MIC) communication (PCI) Traction control lamps (if equipped) Diagnostic communication (PCI, via BUS) REMOVAL (1) Disconnect the battery cables. Fig. 3 CAB Connector Lock 1 - CONNECTOR LOCK 2 - CAB (7) CAB. (8) HCU (9) Disconnect the pump/motor connector from the Remove the screws securing the CAB to the (Fig. 4) Pull CAB straight forward off HCU. INSTALLATION (1) Slide the CAB onto the HCU (Fig. 4). (2) Install screws securing the CAB to the HCU (Fig. 4) Tighten the mounting screws to 2 N·m (17 in lbs). (3) Reconnect the 24–way wiring connector and the pump/motor wiring connector. (Fig. 3) (4) Install the battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - INSTALLATION). (5) Install the screw securing the coolant filler neck to the battery tray. (6) Reconnect the vacuum hose to the coolant tank built into the battery tray. (7) Install the battery (Refer to 8 - ELECTRICAL/ BATTERY SYSTEM/BATTERY - INSTALLATION). (8) Reconnect the battery cables. ELECTRONIC CONTROL MODULES RS 8E - 7 CONTROLLER ANTILOCK BRAKE (Continued) Module (PCM). Refer to On-Board Diagnostics in the General Diagnosis section of this group. FRONT CONTROL MODULE DESCRIPTION Fig. 4 CAB Mounting Screws 1 - HCU 2 - MOUNTING SCREWS 3 - CAB (9) Connect a DRBIIIt to the vehicle and initialize the system. DATA LINK CONNECTOR DESCRIPTION The data link connector is located inside the vehicle, below instrument panel next to the center column (Fig. 5). Fig. 5 DATA LINK CONNECTOR OPERATION The data link connector (diagnostic connector) links the DRB scan tool with the Powertrain Control The Front Control Module (FCM) is a micro controller based module located in the engine compartment. This FCM mates to the power distribution center to form the Integrated Power Module (IPM). The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the Programmable Communications Interface (PCI) data bus. For information on the IPM, (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - DESCRIPTION) OPERATION As messages are sent over the Programmable Communications Interface (PCI) data bus, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are controlled by the Front Control Module: • Accessory Relay Actuation • Brake Transmission Shift Interlock Functions (BTSI) • Diesel Cabin Heater (Diesel Engine Vehicles) • Electronic Back Light (EBL) Rear Defogger • Electronic Transaxle (Gasoline engine Vehicles) • Front and Rear Blower Motor Relay Actuation • Front Fog Lamp Relay Actuation • Front Washer Motor • Front Windshield Wiper “HI” & “LO” Relay Actuation • Front Windshield Wiper “ON” Relay Actuation • Headlamp Power with Voltage Regulation • Horn Relay Actuation • Headlamp Washer Relay Actuation • Name Brand Speaker (NBS) Relay Actuation • Occupant Restraint Controller Voltage • Park Lamp Relay Actuation • Rear Washer Motor • Side Airbag Voltage The following inputs are Received/Monitored by the Front Control Module: • Ambient Temperature Sensing 8E - 8 ELECTRONIC CONTROL MODULES RS FRONT CONTROL MODULE (Continued) • • • • • • • • • • Back-Up switch Brake Fluid Level B+ Connection Detection Engine Crank Signal (Diesel Engine Vehicles) Horn Input Ignition Switch Start Only Ignition Switch Run and Start Only Stop Lamp Sense Washer Fluid Level Windshield Wiper Park DIAGNOSIS AND TESTING - FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any front control module related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB IIIt. The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Fig. 6 REMOVING INTELLIGENT POWER MODULE REMOVAL (1) Disconnect the positive and negative battery cables from the battery. (2) Remove the battery from the vehicle. Refer to the procedure in Battery Systems. (3) Using a long flat-bladed screwdriver, gently twist the Integrated Power Module (IPM) retaining clip outboard to free the IPM from its mounting bracket (Fig. 6). Rotate IPM upward to access the Front Control Module (FCM) retaining screws. (4) Remove the front control module retaining screws. (5) Using both hands, pull the FCM straight from the IPM assembly to disconnect the 49-way electrical connector (Fig. 7) and remove the front control module from the vehicle. INSTALLATION NOTE: Front Control Module must be programmed to the correct radio EQ curve using the DRB IIIT. Fig. 7 FRONT CONTROL MODULE 1 - FRONT CONTROL MODULE This will ensure that the audio system is operating correctly. (1) Install the Front Control Module (FCM) in the Integrated Power Module (IPM) assembly by pushing the 49-way electrical connector straight in. (2) Install the FCM retaining screws. Torque the screws to 1 N·m (7 in. lbs). (3) Rotate the IPM assembly downward to secure in mounting bracket. ELECTRONIC CONTROL MODULES RS 8E - 9 FRONT CONTROL MODULE (Continued) (4) Install the battery in the vehicle. Refer to the procedure in Battery Systems. (5) Connect the positive and negative battery cables. (6) Using the DRB III t, under “FRONT CONTROL MODULE” then “MISC” program the EQ curve of the radio into the Front Control Module. Refer to the appropriate diagnostic manual. NOTE: If the vehicle is not equipped with Name Brand Speakers (Infinity, etc.) or Headlamp Washers the DRB IIIT must be used to Disable the appropriate relays in the Intelligent Power Module Assembly. HEATED SEAT MODULE DESCRIPTION Fig. 8 RS/RG Heated Seat Modules 1 2 3 4 - HEATED SEAT MODULE C1 CONNECTOR C3 CONNECTOR C1 CONNECTOR Vehicles equipped with heated seats utilize two heated seat modules. The heated seat modules (Fig. 8) are located under the front seats, where they are secured to the seat cushion pans. The left heated seat module controls the left heated seat, and the right controls the right. Each heated seat module has three connector receptacles that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the ignition switch, heated seat switch and the heated seat sensor to operate and control the heated seat elements in the front seat and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in the heated seat switch. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. OPERATION The heated seat module operates on fused battery current received from the ignition switch and integrated power module. The module is grounded at all times through the seat wire harness. Inputs to the module include a resistor multiplexed heated seat switch request circuit for the heated seat switch and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch request signal is received by the heated seat module, the module energizes the proper indicator lamp (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. 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). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. DIAGNOSIS AND TESTING - HEATED SEAT MODULE If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Diagnosis and Testing Heated Seat System in Heated Seats for the location of flashing LED heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated 8E - 10 ELECTRONIC CONTROL MODULES RS HEATED SEAT MODULE (Continued) seat switch. Refer to Diagnosis and Testing Heated Seat Switch in Heated Seats for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. (1) Check the heated seat element (Refer to 8 ELECTRICAL/HEATED SEATS/HEATED SEAT ELEMENT - DIAGNOSIS AND TESTING). (2) Check the heated seat sensor (Refer to 8 ELECTRICAL/HEATED SEATS/HEATED SEAT SENSOR - DIAGNOSIS AND TESTING). (3) Check the heated seat switch (Refer to 8 ELECTRICAL/HEATED SEATS/DRIVER HEATED SEAT SWITCH - DIAGNOSIS AND TESTING). NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. (4) Using a voltmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. (5) Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the appropriate front seat from the vehicle (Refer to 23 - BODY/SEATS/SEAT - REMOVAL). (3) Unsnap the module from the seat cushion pan. (4) Disconnect the module wire harness connectors. INSTALLATION (1) Connect the module wire harness connectors. (2) Snap the module on the seat cushion pan. (3) Install the appropriate front seat in the vehicle (Refer to 23 - BODY/SEATS/SEAT - INSTALLATION). (4) Connect and isolate the negative battery cable. POWER LIFTGATE MODULE DESCRIPTION Vehicles equipped with a power liftgate (PLG) utilize a PLG control module. This module is located on the vehicles left side D-pillar just below the motor Fig. 9 LIFTGATE CONTROL MODULE 1 2 3 4 5 - POWER LIFTGATE CONTROL MODULE MODULE RETAINING SCREWS D-PILLAR POWER LIFTGATE MOTOR MODULE ELECTRICAL CONNECTORS assembly (Fig. 9) and contains a microprocessor, which is used to communicate to the vehicles body control module. The PLG control module receives and monitors logic inputs from all the PLG system switches except for the outside handle switch. This module also contains the software technology to detect liftgate obstructions and stop and / or reverse the door accordingly. OPERATION The PLG control module contains the electronic circuitry and software used to control the sequence of events for the PLG system. This module comunicates on the PCI bus circuit with the vehicles body control module to monitor many different inputs and outputs such as door lock status, transmission gear selector position and vehicle speed. Refer to PLG system operation for more information. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove left D-pillar trim panel from the vehicle. Refer to Body for the procedure. (3) Disconnect the wire harness connections from the PLG motor assembly (Fig. 10). ELECTRONIC CONTROL MODULES RS 8E - 11 POWER LIFTGATE MODULE (Continued) POWERTRAIN CONTROL MODULE DESCRIPTION DESCRIPTION The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 11). The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. Fig. 10 LIFTGATE CONTROL MODULE 1 2 3 4 5 - POWER LIFTGATE CONTROL MODULE MODULE RETAINING SCREWS D-PILLAR POWER LIFTGATE MOTOR MODULE ELECTRICAL CONNECTORS (4) Remove the screw holding the PLG control module to the D-pillar (Fig. 10). (5) Remove the PLG control module from the vehicle. INSTALLATION (1) Install the PLG control module on the D-pillar and install retaining screw. Torque the screw to 14.5 in. lbs. (2) Connect the wire harness connections on the PLG control module. Be certain to slide connector locks to the locked position. (3) Install the D-pillar trim panel on the vehicle. Refer to the Body section for the procedure. (4) Connect the negative battery cable. (5) Using an appropriate scan tool, check any erase any PLG control module diagnostic trouble codes. (6) Verify PLG system operation. Cycle the PLG through one complete open and close cycle, this will allow the PLG control module to relearn its cycle with the new components. Fig. 11 Powertrain Control Module (PCM) 1 - Battery 2 - Power Distribution Center 3 - Powertrain Control Module NOTE: PCM Inputs: • • • • • • • ule) • • • Air Conditioning Pressure Transducer ASD Relay Battery Voltage Brake Switch Camshaft Position Sensor Crankshaft Position Sensor Distance Sensor (from transmission control modEGR Position Feedback Engine Coolant Temperature Sensor Heated Oxygen Sensors 8E - 12 ELECTRONIC CONTROL MODULES RS POWERTRAIN CONTROL MODULE (Continued) • • • • • • • • • • • • • • • • ule) Ignition sense Intake Air Temperature Sensor Knock Sensor Leak Detection Pump Feedback Manifold Absolute Pressure (MAP) Sensor Park/Neutral (from transmission control module) PCI Bus Power Steering Pressure Switch Proportional Purge Sense SCI Receive Speed Control Throttle Position Sensor Torque Management Input (From TCM) Transaxle Control Module (TCM) Transaxle Gear Engagement (From TCM) Vehicle Speed (from transmission control mod- NOTE: PCM Outputs: • Air Conditioning Clutch Relay • Automatic Shut Down (ASD) and Fuel Pump Relays • Data Link Connector (PCI and SCI Transmit) • Double Start Override • EGR Solenoid • Fuel Injectors • Generator Field • High Speed Fan Relay • Idle Air Control Motor • Ignition Coils • Leak Detection Pump • Low Speed Fan Relay • MTV Actuator • Proportional Purge Solenoid • SRV Valve • Speed Control Relay • Speed Control Vent Relay • Speed Control Vacuum Relay • 8 Volt Output • 5 Volt Output Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. • Battery Voltage • Intake Air Temperature Sensor • Engine Coolant Temperature • Engine Speed (crankshaft position sensor) • Exhaust Gas Oxygen Content (heated oxygen sensors) • Manifold Absolute Pressure • Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. • Brake Switch • Engine Coolant Temperature • Engine Speed (crankshaft position sensor) • Park/Neutral (transmission gear selection) • Transaxle Gear Engagement • Throttle Position • Vehicle Speed (from Transmission Control Module) The PCM adjusts ignition timing based on the following inputs. • Intake Air Temperature • Engine Coolant Temperature • Engine Speed (crankshaft position sensor) • Knock Sensor • Manifold Absolute Pressure • Park/Neutral (transmission gear selection) • Transaxle Gear Engagement • Throttle Position The automatic shut down (ASD) and fuel pump relays are mounted externally, but turned on and off by the powertrain control module through the same circuit. The camshaft and crankshaft signals are sent to the powertrain control module. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD and fuel pump relays. When these relays are deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts. The 8.0 volts power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volts supply for the engine coolant temperature sensor, intake air temperature sensor, manifold absolute pressure sensor and throttle position sensor. The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the DRB scan tool to change the mileage in the PCM. Refer to the appropriate Powertrain Diagnostic Manual and the DRB scan tool. ELECTRONIC CONTROL MODULES RS 8E - 13 POWERTRAIN CONTROL MODULE (Continued) DIAGNOSTIC TROUBLE CODE DESCRIPTION Remember that DTC’s are the results of a system or circuit failure, but do not directly identify the failed component or components. A Diagnostic Trouble Code (DTC) indicates the PCM has recognized an abnormal condition in the system. NOTE: For a list of DTC’s, refer to the charts in this section. (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0016 Crankshaft/Camshaft Timing Misalignment A rationality error has been detected for camshaft position out of phase with crankshaft P0030 O2 sensor 1/1 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0031 O2 sensor 1/1 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0036 O2 sensor 1/2 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0037 O2 sensor 1/2 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0038 O2 sensor 1/2 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0043 O2 sensor 1/3 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0044 O2 sensor 1/3 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0050 O2 sensor 2/1 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0051 O2 sensor 2/1 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0052 O2 sensor 2/1 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0056 O2 sensor 2/1 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0057 O2 sensor 2/2 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0058 O2 sensor 2/2 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback sense circuit. P0068 Manifold Pressure/Throttle Position Correlation MAP sensor signal does not correlate to throttle position sensor signal. Possible vacuum leak. P0070 Ambient Temp Sensor Stuck A rationality error has been detected in the ambient temp. sensor test. P0071 (M) Ambient Temp Sensor Performance Ambient change less than 3° C in 200 Miles P0072 Ambient Temp Sensor Low Ambient temp. sensor input below the minimum acceptable voltage P0073 Ambient Temp Sensor High Ambient temp. sensor input above the maximum acceptable voltage 8E - 14 ELECTRONIC CONTROL MODULES RS POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0106 (M) Barometric Pressure Out of Range MAP sensor input voltage out of an acceptable range detected during reading of barometric pressure at key-on. P0107 (M) Map Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage. P0108 (M) Map Sensor Voltage Too High MAP sensor input above maximum acceptable voltage. P0110 Intake Air Temp Sensor Stuck A rationality error has been detected for the intake air temp. sensor. P0111 (M) Intake Air Temp Sensor Performance Intake Air change less than 3° C in 200 Miles P0112 (M) Intake Air Temp Sensor Voltage Low Intake air (charge) temperature sensor input below the minimum acceptable voltage. P0113 (M) Intake Air Temp Sensor Voltage High Intake air (charge) temperature sensor input above the maximum acceptable voltage. P0116 Engine Coolant Temp Performance A rationality error has been detected in the coolant temp sensor. P0117 (M) ECT Sensor Voltage Too Low Engine coolant temperature sensor input below the minimum acceptable voltage. P0118 (M) ECT Sensor Voltage Too High Engine coolant temperature sensor input above the maximum acceptable voltage. P0121 (M) TPS Voltage Does Not Agree With MAP TPS signal does not correlate to MAP sensor signal. P0122 (M) Throttle Position Sensor Voltage Low Throttle position sensor input below the acceptable voltage range. P0123 (M) Throttle Position Sensor Voltage High Throttle position sensor input above the maximum acceptable voltage. P0125 (M) Engine Coolant Temp Not Reached Time to enter Closed Loop Operation (Fuel Control) is excessive. P0128 Thermostat Rationality A rationality error has been detected for the thermostat P0129 Barometic Pressure Out-of-Range low MAP sensor input voltage out of an acceptable range detected during reading of barometric pressure. P0130 1/1 O2 Sensor Heater Relay Circuit An open or shorted condition detected in the ASD or CNG shutoff relay control ckt. P0131 (M) 1/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal operating range. P0132 (M) 1/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal operating range. P0133 (M) 1/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency. P0134 (M) 1/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen sensor input. P0135 (M) 1/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction. P0136 1/2 O2 Sensor Heater Relay Circuit An open or shorted condition detected in the ASD or CNG shutoff relay control ckt. P0137 (M) 1/2 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal operating range. ELECTRONIC CONTROL MODULES RS 8E - 15 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0138 (M) 1/2 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal operating range. P0139 (M) 1/2 O2 Sensor Slow Response Oxygen sensor response not as expected. P0140 (M) 1/2 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen sensor. P0141 (M) 1/2 O2 Sensor Heater Failure Oxygen sensor heater element malfunction. P0143 1/3 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal operating range. P0144 1/3 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal operating range. P0145 1/3 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency. P0146 1/3 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen sensor. P0147 1/3 O2 Sensor Heater Failure Oxygen sensor heater element malfunction. P0151 (M) 2/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal operating range. P0152 (M) 2/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage sustained above normal operating range. P0153 (M) 2/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency. P0154 (M) 2/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen sensor. P0155 (M) 2/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction. P0157 (M) 2/2 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal operating range. P0158 (M) 2/2 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal operating range. P0159 2/2 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency. P0160 (M) 2/2 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen sensor. P0161 (M) 2/2 O2 Sensor Heater Failure Oxygen sensor heater element malfunction. P0165 Starter Relay Circuit P0171 (M) 1/1 Fuel System Lean A lean air/fuel mixture has been indicated by an abnormally rich correction factor. P0172 (M) 1/1 Fuel System Rich A rich air/fuel mixture has been indicated by an abnormally lean correction factor. P0174 (M) 2/1 Fuel System Lean A lean air/fuel mixture has been indicated by an abnormally rich correction factor. P0175 (M) 2/1 Fuel System Rich A rich air/fuel mixture has been indicated by an abnormally lean correction factor. P0176 Flex Fuel Calibration Signal No calibration voltage present from flex fuel sensor. 8E - 16 ELECTRONIC CONTROL MODULES RS POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0178 Flex Fuel Sensor Volts Too Low Flex fuel sensor input below minimum acceptable voltage. P0179 Flex Fuel Sensor Volts Too High Flex fuel sensor input above maximum acceptable voltage. P0201 (M) Injector #1 Control Circuit An open or shorted condition detected in control circuit for injector #1 or the INJ 1 injector bank. P0202 (M) Injector #2 Control Circuit An open or shorted condition detected in control circuit for injector #2 or the INJ 2 injector bank. P0203 (M) Injector #3 Control Circuit An open or shorted condition detected in control circuit for injector #3 or the INJ 3 injector bank. P0204 (M) Injector #4 Control Circuit Injector #4 or INJ 4 injector bank output driver stage does not respond properly to the control signal. P0205 (M) Injector #5 Control Circuit Injector #5 output driver stage does not respond properly to the control signal. P0206 (M) Injector #6 Control Circuit Injector #6 output driver stage does not respond properly to the control signal. P0207 Injector #7 Control Circuit Injector #7 output driver stage does not respond properly to the control signal. P0208 Injector #8 Control Circuit Injector #8 output driver stage does not respond properly to the control signal. P0209 Injector #9 Control Circuit Injector #9 output driver stage does not respond properly to the control signal. P0210 Injector #10 Control Circuit Injector #10 output driver stage does not respond properly to the control signal. P0234 Boost Limit Exceeded P0243 Wastegate Solenoid Circuit P0300 (M) Multiple Cylinder Mis-fire Misfire detected in multiple cylinders. P0301 (M) CYLINDER #1 MISFIRE Misfire detected in cylinder #1. P0302 (M) CYLINDER #2 MISFIRE Misfire detected in cylinder #2. P0303 (M) CYLINDER #3 MISFIRE Misfire detected in cylinder #3. P0304 (M) CYLINDER #4 MISFIRE Misfire detected in cylinder #4. P0305 (M) CYLINDER #5 MISFIRE Misfire detected in cylinder #5. P0306 (M) CYLINDER #6 MISFIRE Misfire detected in cylinder #6. P0307 (M) CYLINDER #7 MISFIRE Misfire detected in cylinder #7 P0308 (M) CYLINDER #8 MISFIRE Misfire detected in cylinder #8. P0309 (M) CYLINDER #9 MISFIRE Misfire detected in cylinder #9. P0310 (M) CYLINDER #10 MISFIRE Misfire detected in cylinder #10. P0315 No Crank Sensor Learned Unable to learn the crank senor’s signal in preparation for misfire diagnostics. P0320 No Crank Reference Signal at PCM No reference signal (crankshaft position sensor) detected during engine cranking. P0325 Knock Sensor #1 Circuit Knock sensor (#1) signal above or below minimum acceptable threshold voltage at particular engine speeds. ELECTRONIC CONTROL MODULES RS 8E - 17 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0330 Knock Sensor #2 Circuit Knock sensor (#2) signal above or below minimum acceptable threshold voltage at particular engine speeds. P0335 Crankshaft Position Sensor Circuit A rationality error has been detected for loss of crankshaft position sensor. P0339 Crankshaft Position Sensor Circuit Intermittent A rationality error has been detected for intermittent loss of crankshaft position sensor. P0340 (M) Camshaft Position Sensor Circuit A rationality error has been detected for loss of camshaft position sensor. P0344 Camshaft Position Sensor Circuit Intermittent A rationality error has been detected for intermittent loss of camshaft position sensor. P0350 Ignition Coil Draws Too Much Current A coil (1-5) is drawing too much current. P0351 (M) Ignition Coil Primary # 1 Circuit Peak primary circuit current not achieved with maximum dwell time. P0352 (M) Ignition Coil Primary # 2 Circuit Peak primary circuit current not achieved with maximum dwell time. P0353 (M) Ignition Coil Primary # 3 Circuit Peak primary circuit current not achieved with maximum dwell time. P0354 (M) Ignition Coil Primary# 4 Circuit Peak primary circuit current not achieved with maximum dwell time (High Impedance). P0355 (M) Ignition Coil Primary # 5 Circuit Peak primary circuit current not achieved with maximum dwell time (High Impedance). P0356 (M) Ignition Coil Primary # 6 Circuit Peak primary circuit current not achieved with maximum dwell time (high impedance). P0357 Ignition Coil Primary # 7 Circuit Peak primary circuit current not achieved with maximum dwell time (high impedance). P0358 Ignition Coil Primary # 8 Circuit Peak primary circuit current not achieved with maximum dwell time (high impedance). P0400 Diesel EGR System Failure P0401 (M) EGR System Failure Required change in air/fuel ration not detected during diagnostic test. P0403 (M) EGR Solenoid Circuit An open or shorted condition detected in the EGR solenoid control circuit. P0404 (M) EGR Position Sensor Rationality EGR position sensor signal does not correlate to EGR duty cycle. P0405 (M) EGR Position Sensor Volts Too Low EGR position sensor input below the acceptable voltage range. P0406 (M) EGR Position Sensor Volts Too High EGR position sensor input above the acceptable voltage range. P0412 Secondary Air Solenoid Circuit An open or shorted condition detected in the secondary air (air switching/aspirator) solenoid control circuit. P0420 (M) 1/1 Catalytic Converter Efficiency Catalyst 1/1 efficiency below required level. P0432 (M) 1/2 Catalytic Converter Efficiency Catalyst 2/1 efficiency below required level. P0440 General EVAP System Failure General system failure. 8E - 18 ELECTRONIC CONTROL MODULES RS POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0441 (M) Evap Purge Flow Monitor Insufficient or excessive vapor flow detected during evaporative emission system operation. P0442 (M) Evap Leak Monitor 0.040 Leak Detected A 0.040 leak has been detected in the evaporative system. P0443 (M) Evap Purge Solenoid Circuit An open or shorted condition detected in the EVAP purge solenoid control circuit. P0452 NVLD Pressure Switch Stuck Closed NVLD pressure switch stuck closed. P0453 NVLD Pressure Switch Stuck Open NVLD pressure switch stuck open. P0455 (M) Evap Leak Monitor Large Leak Detected A large leak has been detected in the evaporative system. P0456 (M) Evap Leak Monitor 0.020 Leak Detected A 0.020 leak has been detected in the evaporative system. P0460 Fuel Level Unit No Change Over Miles No movement of fuel level sender detected. P0461 Fuel Level Unit No Changeover Time No level of fuel level sender detected. P0462 Fuel Level Sending Unit Volts Too Low Fuel level sensor input below acceptable voltage. P0463 Fuel Level Sending Unit Volts Too High Fuel level sensor input above acceptable voltage. P0480 Low Speed Fan Relay Control Circuit An open or shorted condition detected in the low speed rad. fan relay control circuit. P0481 High Speed Fan Relay Control Circuit An open or shorted condition detected in the high speed rad. fan relay control circuit. P0498 NVLD Canister Vent Valve Solenoid Circuit Low A shorted low condition detected in NVLD solenoid circuit. P0499 NVLD Canister Vent Valve Solenoid Circuit High A shorted high condition detected in NVLD solenoid circuit. P0500 (M) No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load conditions. P0501 Vehicle Speed Sensor #1 Performance A rationality error has been detected for no vehicle speed sensor signal detected during road load conditions. P0505 (M) Idle Air Control Motor Circuits Replace idle air control motor. P0508 (M) Idle Air Control Motor Circuit Low Idle Air Control Motor Circuit input below acceptable current P0509 (M) Idle Air Control Motor Circuit High Idle Air Control Motor Circuit input above acceptable current P0511 Idle Air Control Valve Solenoid Circuit An open or shorted condition detected in the IAC control circuit. P0513 Invalid SKIM Key The engine controller has received an invalid key from the Smart Key Immobilizer Module. P0516 Battery Temperature Sensor Low Battery Temp. sensor input below minimum acceptable voltage. P0517 Battery Temperature Sensor High Battery Temp. sensor input above maximum acceptable voltage. P0519 Idle Speed Performance A rationality error has been detected for target RPM not met during drive idle condition. Possible Vacuum leak or IAC lost steps. ELECTRONIC CONTROL MODULES RS 8E - 19 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0522 Oil Pressure Sens Low Oil pressure sensor input below acceptable voltage. P0523 Oil Pressure Sens High Oil pressure sensor input above acceptable voltage. P0532 A/C Pressure Sensor Low A/C pressure sensor input below the minimum acceptable voltage. P0533 A/C Pressure Sensor High A/C pressure sensor input above the maximum acceptable voltage. P0551 (M) Power Steering Switch Failure Incorrect input state detected for the power steering switch circuit. PL: High pressure seen at high speed. P0562 Battery Voltage Low Battery voltage sense input below the minimum acceptable voltage. P0563 Battery Voltage High Battery voltage sense input above the maximum acceptable voltage. P0579 Speed Control Switch #1 Performance Cruise switch stuck in a valid voltage range. P0580 Speed Control Switch #1 Low Speed control switch input below minimum acceptable voltage. P0581 Speed Control Switch #1 High Speed control switch input above maximum acceptable voltage. P0582 Speed Control Vacuum Solenoid Circuit An open or shorted condition detected in speed control Vacuum solenoid control circuit. P0586 Speed Control Vent Solenoid Circuit An open or shorted condition detected in speed control vent solenoid control circuit. P0594 Speed Control Servo Power Circuit An open or shorted condition open/short condition detected in the speed control servo power control circuit. P0600 (M) PCM Failure SPI Communications No communication detected between co-processors in the control module. P0601 (M) Internal Controller Failure Internal control module fault condition (check sum) detected. P0604 Internal Trans Controller Transmission control module RAM self test fault detected. -Aisin transmission. P0605 Internal Trans Controller Transmission control module ROM self test fault detected -Asian transmission. P0615 Starter Relay Circuit Open or shorted condition detected in the starter relay control circuit. P0622 (G) Generator Field Not Switching Properly An open or shorted condition detected in the generator field control circuit. P0627 Fuel Pump Relay Circuit An open or shorted condition detected in the fuel pump relay control circuit. P0630 VIN Not Programmed In PCM VIN is not programmed in the control module EEPROM. P0632 Odometer Not Programmed In PCM Odometer is not programmed in the control module EEPROM. P0633 SKIM Key Not Programmed In PCM SKIM secert key is not programmed in the control module EEPROM. P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch relay control circuit. 8E - 20 ELECTRONIC CONTROL MODULES RS POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0660 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold tuning valve solenoid control circuit. P0685 ASD Relay Control Circuit An open or shorted condition detected in the ASD relay control circuit. P0688 ASD Relay Sense Circuit Low ASD voltage sensed when ASD relay is energized or ASD voltage not sensed when ASD relay is not energized. P0700 (M) Check Transmission DTC’s This SBEC III or JTEC DTC indicates that the EATX has an active fault and has requested illuminated the MIL via a BUS message. The specific fault must be acquired from the EATX. P0703 (M) Brake Switch Stuck Pressed or Released Incorrect input state detected in the brake switch circuit. (Changed from P1595). P0711 Trans Temp Sensor, No Temp Rise After Start Relationship between the transmission temperature and overdrive operation and/or TCC operation indicates a failure of the Transmission Temperature Sensor. OBD II Rationality. P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below acceptable voltage. P0713 Trans Temp Sensor Voltage Too High Transmission fluid temperature sensor input above acceptable voltage. P0720 Low Output SPD Sensor RPM, Above 15 MPH The relationship between the Output Shaft Speed Sensor and vehicle speed is not within acceptable limits. P0740 (M) Torque Con Clu, No RPM Drop at Lockup Relationship between engine and vehicle speeds indicated failure of torque convertor clutch lock-up system (TCC/PTU sol). P0743 Torque Converter Clutch Solenoid/ Trans Relay Circuits An open or shorted condition detected in the torque converter clutch (part throttle unlock) solenoid control circuit. Shift solenoid C electrical fault - Asian transmission P0748 Governor Pressure Sol Control/Trans Relay Circuits An open or shorted condition detected in the Governor Pressure Solenoid circuit or Trans Relay Circuit in JTEC RE transmissions. P0751 O/D Switch Pressed (Lo) More Than 5 Minutes Overdrive override switch input is in a prolonged depressed state. P0753 Trans 3-4 Shift Sol/Trans Relay Circuits An open or shorted condition detected in the overdrive solenoid control circuit or Trans Relay Circuit in JTEC RE transmissions. P0756 AW4 Shift Sol B (2-3) Functional Failure Shift solenoid B (2-3) functional fault - Asian transmission P0783 3-4 Shift Sol, No RPM Drop at Lockup The overdrive solenoid is unable to engage the gear change from 3rd gear to the overdrive gear. P0801 Reverse Gear Lockout Circuit Open or Short An open or shorted condition detected in the transmission reverse gear lock-out solenoid control circuit. P0833 Clutch Upstop Switch Performance Rationality error detected for clutch upstop switch performance ELECTRONIC CONTROL MODULES RS 8E - 21 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0850 Park/Natural Switch Performance A rationality error has been detected for park/neutral switch performance. P1105 Baro Read Solenoid Circuit Open or shorted condition detected in the baro read solenoid control circuit. P1115 General Temperature Rationality General temperature sensor rationality error. P1192 (M) Inlet Air Temp. Circuit Low Inlet Air Temp. sensor input below acceptable voltage P1193 (M) Inlet Air Temp. Circuit High Inlet Air Temp. sensor input above acceptable voltage. P1194 PWM O2 Heater Performance Incorrect or irrational performance has been detected for the PWM O2 heater circuit. P1195 (M) 1/1 O2 Sensor Slow During Catalyst Monitor A slow switching oxygen sensor has been detected in bank 1/1 during catalyst monitor test. (was P0133) P1196 (M) 2/1 O2 Sensor Slow During Catalyst Monitor A slow switching oxygen sensor has been detected in bank 2/1 during catalyst monitor test. (was P0153) P1197 1/2 O2 Sensor Slow During Catalyst Monitor A slow switching oxygen sensor has been detected in bank 1/2 during catalyst monitor test. (was P0139) P1198 Radiator Temperature Sensor Volts Too High Radiator coolant temperature sensor input above the maximum acceptable voltage. P1199 Radiator Temperature Sensor Volts Too Low Radiator coolant temperature sensor input below the minimum acceptable voltage. P1281 Engine is Cold Too Long Engine coolant temperature remains below normal operating temperatures during vehicle travel (Thermostat). P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump relay control circuit. P1288 Intake Manifold Short Runner Solenoid Circuit An open or shorted condition detected in the short runner tuning valve circuit. P1289 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold tuning valve solenoid control circuit. P1290 CNG Fuel System Pressure Too High Compressed natural gas system pressure above normal operating range. P1291 No Temp Rise Seen From Intake Heaters Energizing Heated Air Intake does not change intake air temperature sensor an acceptable amount. P1292 CNG Pressure Sensor Voltage Too High Compressed natural gas pressure sensor reading above acceptable voltage. P1293 CNG Pressure Sensor Voltage Too Low Compressed natural gas pressure sensor reading below acceptable voltage. P1294 (M) Target Idle Not Reached Target RPM not achieved during drive idle condition. Possible vacuum leak or IAC (AIS) lost steps. P1295 No 5 Volts to TP Sensor Loss of a 5 volt feed to the Throttle Position Sensor has been detected. P1296 No 5 Volts to MAP Sensor Loss of a 5 volt feed to the MAP Sensor has been detected. P1297 (M) No Change in MAP From Start To Run No difference is recognized between the MAP reading at engine idle and the stored barometric pressure reading. 8E - 22 ELECTRONIC CONTROL MODULES RS POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P1298 Lean Operation at Wide Open Throttle A prolonged lean condition is detected during Wide Open Throttle. P1299 (M) Vacuum Leak Found (IAC Fully Seated) MAP Sensor signal does not correlate to Throttle Position Sensor signal. Possible vacuum leak. P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the ASD or CNG shutoff relay control ckt. P1389 No ASD Relay Output Voltage At PCM No Z1 or Z2 voltage sensed when the auto shutdown relay is energized. P1390 (M) Timing Belt Skipped 1 Tooth or More Relationship between Cam and Crank signals not correct. P1391 (M) Intermittent Loss of CMP or CKP Loss of the Cam Position Sensor or Crank Position sensor has occurred. For PL 2.0L P1398 (M) Mis-Fire Adaptive Numerator at Limit PCM is unable to learn the Crank Sensor’s signal in preparation for Misfire Diagnostics. Probable defective Crank Sensor. P1399 Wait To Start Lamp Circuit An open or shorted condition detected in the Wait to Start Lamp circuit. P1403 No 5 Volts to EGR Sensor Loss of 5v feed to the EGR position sensor. P1476 Too Little Secondary Air Insufficient flow of secondary air injection detected during aspirator test.(was P0411) P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during aspirator test (was P0411). P1478 (M) Battery Temp Sensor Volts Out of Limit Internal temperature sensor input voltage out of an acceptable range. P1479 Transmission Fan Relay Circuit An open or shorted condition detected in the transmission fan relay circuit. P1480 PCV Solenoid Circuit An open or shorted condition detected in the PCV solenoid circuit. P1481 EATX RPM Pulse Performance ETAX RPM pulse generator signal for misfire detection does not correlate with expected value. P1482 Catalyst Temperature Sensor Circuit Shorted Low Catalyst temperature sensor circuit shorted low. P1483 Catalyst Temperature Sensor Circuit Shorted High. Catalyst temperature sensor circuit shorted high. P1484 Catalytic Converter Overheat Detected A catalyst overheat condition has been detected by the catalyst temperature sensor. P1485 Air Injection Solenoid Circuit An open or shorted condition detected in the air assist solenoid circuit. P1486 (M) Evap Leak Monitor Pinched Hose Found LDP has detected a pinched hose in the evaporative hose system. P1487 Hi Speed Rad Fan CTRL Relay Circuit An open or shorted condition detected in the control circuit of the #2 high speed radiator fan control relay. P1488 Auxiliary 5 Volt Supply Output Too Low Auxiliary 5 volt sensor feed is sensed to be below an acceptable limit. ELECTRONIC CONTROL MODULES RS 8E - 23 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P1489 (M) High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control circuit of the high speed radiator fan control relay. P1490 (M) Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of the low speed radiator fan control relay. P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan control relay control circuit. This includes PWM solid state relays. P1492 (M,G) Ambient/Batt Temp Sen Volts Too High External temperature sensor input above acceptable voltage. P1493 (M,G) Ambient/Batt Temp Sen Volts Too Low External temperature sensor input below acceptable voltage. P1494 (M) Leak Detection Pump Sw or Mechanical Fault Incorrect input state detected for the Leak Detection Pump (LDP) pressure switch. P1495 (M) Leak Detection Pump Solenoid Circuit An open or shorted condition detected in the Leak Detection Pump (LDP) solenoid circuit. P1496 (M) 5 Volt Supply, Output Too Low 5 volt sensor feed is sensed to be below an acceptable limit. ( < 4v for 4 sec ). P1498 High Speed Rad Fan Ground CTRL Rly Circuit An open or shorted condition detected in the control circuit of the #3 high speed radiator fan control relay. P1594 (G) Charging System Voltage Too High Battery voltage sense input above target charging voltage during engine operation. P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the speed control vacuum or vent solenoid control circuits. P1596 Speed Control Switch Always High Speed control switch input above maximum acceptable voltage. P1597 Speed Control Switch Always Low Speed control switch input below minimum acceptable voltage. P1598 A/C Pressure Sensor Volts Too High A/C pressure sensor input above maximum acceptable voltage. P1599 A/C Pressure Sensor Volts Too Low A/C pressure sensor input below minimum acceptable voltage. P1602 (M) PCM not Programmed PCM not programmed (generic controller fault). P1603 PCM Internal Dual Port Ram Communication Dual port RAM communication link error. P1604 PCM Internal Dual Port Ram Read/Write Integrity Failure Dual port RAM read/write error. P1607 PCM internal Shutdown Timer Rationality A rationality error has been detected for the shutdown timer. P1680 Clutch Released Switch Circuit P1681 No I/P Cluster CCD/J1850 Messages Received No CCD/J1850 messages received from the cluster control module. P1682 (G) Charging System Voltage Too Low Battery voltage sense input below target charging voltage during engine operation and no significant change in voltage detected during active test of generator output circuit. 8E - 24 ELECTRONIC CONTROL MODULES RS POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P1683 SPD CTRL PWR Relay; or S/C 12v Driver CKT An open or shorted condition detected in the speed control servo power control circuit. (SBECII: ext relay). P1684 Battery Loss In The Last 50 Starts The battery has been disconnected within the last 50 starts. P1685 Skim Invalid Key The engine controller has received an invalid key from the SKIM. P1686 No SKIM BUS Messages Received No CCD/J1850 messages received from the Smart Key Immobilizer Module (SKIM). P1687 No MIC BUS Message No CCD/J1850 messages received from the Mechanical Instrument Cluster (MIC) module. P1693 DTC Detected in Companion Module A fault has been generated in the companion engine control module. P1694 Fault In Companion Module No CCD/J1850 messages received from the powertrain control module-Aisin transmission. P1695 No CCD/J1850 Message From Body Control Module No CCD/J1850 messages received from the body control module. P1696 (M) PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by the control module. P1697 (M) PCM Failure SRI Mile Not Stored Unsuccessful attempt to update Service Reminder Indicator (SRI or EMR) mileage in the control module EEPROM. P1698 (M) No CCD/J1850 Message From TCM No CCD/J1850 messages received from the electronic transmission control module (EATX) or the Aisin transmission controller. P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission 2-3 gear lock-out solenoid control circuit. P1740 TCC or O/D Solenoid Performance Rationality error detected in either the torque convertor clutch or solenoid or overdrive solenoid system. P1756 GOV Press Not Equal to Target @ 15-20 PSI The requested pressure and the actual pressure are not within a tolerance band for the Governor Control System which is used to regulate governor pressure to control shifts for 1st, 2nd, and 3rd gear. (Mid Pressure Malfunction) P1757 GOV Press Not Equal to Target @ 15-20 PSI The requested pressure and the actual pressure are not within a tolerance band for the Governor Control System which is used to regulate governor pressure to control shifts for 1st, 2nd, and 3rd gear (Zero Pressure Malfunction) P1762 Gov Press Sen Offset Volts Too Low or High The Governor Pressure Sensor input is greater than a calibration limit or is less than a calibration limit for 3 consecutive park/neutral calibrations. P1763 Governor Pressure Sensor Volts Too Hi The Governor Pressure Sensor input is above an acceptable voltage level. P1764 Governor Pressure Sensor Volts Too Low The Governor Pressure Sensor input is below an acceptable voltage level. P1765 Trans 12 Volt Supply Relay CTRL Circuit An open or shorted condition is detected in the Transmission Relay control circuit. This relay supplies power to the TCC P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch. ELECTRONIC CONTROL MODULES RS 8E - 25 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P2008 Short Runner Valve Solenoid Circuit An open or shorted condition detected in the short runner tuning valve control circuit. P2302 Ignition Coil Secondary #1 Circuit P2305 Ignition Coil Secondary #2 Circuit P2308 Ignition Coil Secondary #3 Circuit P2311 Ignition Coil Secondary #4 Circuit P2314 Ignition Coil Secondary #5 Circuit P2317 Ignition Coil Secondary #6 Circuit P2320 Ignition Coil Secondary #7 Circuit P2323 Ignition Coil Secondary #8 Circuit P2503 Charging System Voltage Low OPERATION - SENSOR RETURN - PCM INPUT Charging system voltage below minimum acceptable voltage. OPERATION 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). The PCM supplies 8 volts to the crankshaft position sensor, camshaft position sensor. OPERATION - SCI RECEIVE - PCM INPUT OPERATION - 5 VOLT SUPPLY - PCM OUTPUT SCI Receive is the serial data communication receive circuit for the DRB scan tool. The Powertrain Control Module (PCM) receives data from the DRB through the SCI Receive circuit. OPERATION - IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. OPERATION - PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as three different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side of any relay, solenoid, ignition coil or injector. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The SBEC III 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 case is also grounded separately from the ground pins. OPERATION - 8-VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: • A/C pressure transducer • Engine coolant temperature sensor • Manifold absolute pressure sensor • Throttle position sensor • Linear EGR solenoid • Battery temperature • Knock sensor STANDARD PROCEDURE - OBTAINING DIAGNOSTIC TROUBLE CODES BULB CHECK Key on: Bulb illuminated until vehicle starts, as long as all once per trip (readiness) monitors completed. If monitors have not been completed, then: Key on: bulb check for about 8 seconds, lamp then flashes if once per trip (readiness) monitors have not been completed until vehicle is started, then MIL is extinguished. OBTAINING DTC’S USING DRB SCAN TOOL (1) Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column. 8E - 26 ELECTRONIC CONTROL MODULES RS POWERTRAIN CONTROL MODULE (Continued) (2) Turn the ignition switch on and access the “Read Fault” screen. (3) Record all the DTC’s and “freeze frame” information shown on the DRB scan tool. (4) To erase DTC’s, use the “Erase Trouble Code” data screen on the DRB scan tool. Do not erase any DTC’s until problems have been investigated and repairs have been performed. (4) Remove the 2 PCM connectors. (5) Remove the headlamp, refer to the Lamps section for more information. (6) Remove the lower PCM mounting bolt (Fig. 13). OBTAINING DTC’S USING IGNITION KEY (1) Cycle the ignition key On - Off - On - Off - On within 5 seconds. (2) The Odometer will show the P-code for the DTC code number. Refer to the Emission section for the DTC chart for a detailed explanation of the DTC codes. (3) If no DTC’s are present, the cluster will display one of two texts: “P1684” and “done” or only “done”. • P1684 is only a status and indicates that the PCM memory has been cleared within the last 50 ignition cycles and does not indicate a problem. • done indicates that NO DTCs are present and the procedure is complete. REMOVAL (1) Disconnect the negative battery cable. (2) Remove the battery shield, refer to the Battery section for more information. (3) Remove the 2 upper PCM bracket bolts (Fig. 12). Fig. 13 PCM LOWER BOLT (7) Remove PCM. INSTALLATION (1) Install the PCM. (2) Install the lower PCM mounting bolt. Tighten bolt. (3) Install the 2 upper PCM bracket bolts. Tighten bolt. (4) Install the headlamp, refer to the Lamps section for more information. (5) Install the 2 PCM connectors. (6) Install the battery shield, refer to the Battery section for more information. (7) Connect the negative battery cable. SENTRY KEY IMMOBILIZER MODULE DESCRIPTION Fig. 12 PCM 1 - Attaching Bolts The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKIM retains in memory the ID numbers of any Sentry Key that is programmed to it. The maximum number of keys that may be programmed to each module is eight (8). The SKIM also communicates over the PCI bus with the Powertrain Control Module (PCM), the Body Control Module RS ELECTRONIC CONTROL MODULES 8E - 27 SENTRY KEY IMMOBILIZER MODULE (Continued) The SKIM also sends indicator light status messages to the BCM to operate the light. This is the method used to turn the light ON solid or to flash it after the indicator light test is complete to signify a fault in the SKIS. If the light comes ON and stays ON solid after the indicator light test, this signifies that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key OR a key-related fault exists, the indicator light will flash following the indicator light test. The SKIM may also request an audible chime if the customer key programming feature is available and the procedure is being utilized (Refer to 8 - ELECTRICAL/VEHICLE THEFT SECURITY/TRANSPONDER KEY - STANDARD PROCEDURE). (BCM), and the DRB IIIt scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring formation that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring fits snugly around the circumference of the ignition lock cylinder housing. If this ring is not mounted properly, communication problems may arise in the form of transponder-related faults. For added system security, each SKIM is programmed with a unique 9Secret Key9 code. This code is stored in memory and is sent over the PCI bus to the PCM and to each key that is programmed to work with the vehicle. The 9Secret Key9 code is therefore a common element found in all components of the Sentry Key Immobilizer System (SKIS). In the event that a SKIM replacement is required, the 9Secret Key9 code can be restored from the PCM by following the SKIM replacement procedure found in the DRB IIIt scan tool. Proper completion of this task will allow the existing ignition keys to be reprogrammed. Therefore, new keys will NOT be needed. In the event that the original 9Secret Key9 code can not be recovered, new ignition keys will be required. The DRB IIIt scan tool will alert the technician if key replacement is necessary. Another security code, called a PIN, is used to gain secured access to the SKIM for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a bus message from the assembly plant tester. The SKIS scrambles the information that is communicated between its components in order to reduce the possibility of unauthorized SKIM access and/or disabling. (1) Disconnect and isolate the battery negative cable. (2) Remove Lower Instrument Panel Cover. Refer to Body, Instrument Panel, Lower Instrument Panel Cover, Removal. (3) Remove the steering column upper and lower shrouds. Refer to Steering, Column, Column Shroud, Removal. (4) Disengage the steering column wire harness from the Sentry Key Immobilizer Module (SKIM). (5) Remove the one screws securing the SKIM to the steering column. (6) Rotate the SKIM upwards and then to the side away from the steering column to slide the SKIM antenna ring from around the ignition switch lock cylinder housing. (7) Remove the SKIM from the vehicle. OPERATION INSTALLATION When the ignition switch is moved to the RUN position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM then waits for a response RF signal from the transponder in the key. If the response received identifies the key as valid, the SKIM sends a 9valid key9 message to the PCM over the PCI bus. If the response received identifies the key as invalid or no response is received from the transponder in the ignition key, the SKIM sends an 9invalid key9 message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM is 9invalid key.9 Therefore, if no response is received by the PCM, the engine will be immobilized after two (2) seconds of running. (1) Slip the SKIM antenna ring around the ignition switch lock cylinder housing. Rotate the SKIM downwards and then towards the steering column. (2) Install the one screws securing the SKIM to the steering column. (3) Engage the steering column wire harness from the Sentry Key Immobilizer Module (SKIM). (4) Install the steering column upper and lower shrouds. Refer to Steering, Column, Column Shroud, Installation. (5) Install the Lower Instrument Panel Cover. Refer to Body, Instrument Panel, Lower Instrument Panel Cover, Installation. (6) Connect the battery negative cable. REMOVAL 8E - 28 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE DESCRIPTION The Transmission Control Module (TCM) is located behind the left fender and is fastened with three screws to three clips in the left frame rail forward of the suspension (Fig. 14). Fig. 14 Transmission Control Module (TCM) Location 1 - TRANSMISSION CONTROL MODULE (TCM) OPERATION The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. RS Some examples of direct inputs to the TCM are: • Battery (B+) voltage • Ignition “ON” voltage • Transmission Control Relay (Switched B+) • Throttle Position Sensor • Crankshaft Position Sensor (CKP) • Transmission Range Sensor (TRS) • Pressure Switches (L/R, 2/4, OD) • Transmission Temperature Sensor (Integral to TRS) • Input Shaft Speed Sensor • Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: • Engine/Body Identification • Manifold Pressure • Target Idle • Torque Reduction Confirmation • Speed Control ON/OFF Switch • Engine Coolant Temperature • Ambient/Battery Temperature • Brake Switch Status • DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: • Transmission Control Relay • Solenoids (LR/CC, 2/4, OD and UD) • Vehicle Speed (to PCM) • Torque Reduction Request (to PCM) An example of a TCM indirect output is: • Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: • Storing and maintaining Clutch Volume Indices (CVI) • Storing and selecting appropriate Shift Schedules • System self-diagnostics • Diagnostic capabilities (with DRB scan tool) ELECTRONIC CONTROL MODULES RS 8E - 29 TRANSMISSION CONTROL MODULE (Continued) CLUTCH VOLUME INDEX (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 15). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the “Monitors” display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range Fig. 15 Example of CVI Calculation 1 2 3 4 5 6 7 8 - OUTPUT SPEED SENSOR OUTPUT SHAFT CLUTCH PACK SEPARATOR PLATE FRICTION DISCS INPUT SHAFT INPUT SPEED SENSOR PISTON AND SEAL clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: CLUTCH VOLUMES Clutch L/R When Updated Shift Sequence Oil Temperature Throttle Angle Proper Clutch Volume 2-1 or 3-1 coast downshift > 70° < 5° 35 to 83 2/4 1-2 shift OD 2-3 shift UD 4-3 or 4-2 shift > 110° 5 - 54° > 5° 20 to 77 48 to 150 24 to 70 8E - 30 ELECTRONIC CONTROL MODULES RS TRANSMISSION CONTROL MODULE (Continued) SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: • Shift lever position • Throttle position • Engine load Schedule • Fluid temperature • Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Condition Expected Operation Extreme Cold Oil temperature at start-up below -16° F Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold Oil temperature at start-up above -12° F and below 36° F – Delayed 2-3 upshift (approximately 22-31 mph) – Delayed 3-4 upshift (45-53 mph) – Early 4-3 costdown shift (approximately 30 mph) – Early 3-2 coastdown shift (approximately 17 mph) – High speed 4-2, 3-2, 2-1 kickdown shifts are prevented – No EMCC Warm Oil temperature at start-up above 36° F and below 80 degree F – Normal operation (upshift, kickdowns, and coastdowns) – No EMCC Hot Oil temperature at start-up above 80° F – Normal operation (upshift, kickdowns, and coastdowns) – Full EMCC, no PEMCC except to engage FEMCC (except at closed throttle at speeds above 70-83 mph) Overheat Oil temperature above 240° F or engine coolant temperature above 244° F – Delayed 2-3 upshift (25-32 mph) – Delayed 3-4 upshift (41-48 mph) – 3rd gear FEMCC from 30-48 mph – 3rd gear PEMCC from 27-31 mph Super Overheat Oil temperature above 260° F – All 9Overheat9 shift schedule features apply – 2nd gear PEMCC above 22 mph – Above 22 mph the torque converter will not unlock unless the throttle is closed or if a wide open throttle 2nd PEMCC to 1 kickdown is made RS STANDARD PROCEDURE STANDARD PROCEDURE - PINION FACTOR SETTING NOTE: This procedure must be performed if the Transmission Control Module (TCM) 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 TCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Transmission 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 DRBIIIt scan tool. (1) Plug the DRBIIIt 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 DRBIIIt scan tool screen. ELECTRONIC CONTROL MODULES 8E - 31 (1) Plug the DRBIIIt scan tool into the diagnostic connector. The connector is located under the instrument panel. (2) Go to the Transmission screen. (3) Go to the Miscellaneous screen. (4) Select Quick Learn Procedure. Follow the instructions of the DRBIIIt to perform the Quick Learn Procedure. REMOVAL NOTE: If transmission control module is being replaced with a new or replacement unit, the Pinion Factor and Quick Learn procedures must be performed. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to 8 ELECTRICAL/ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (1) Disconnect battery negative cable. (2) Raise vehicle on hoist. (3) Remove left front tire/wheel assembly. (4) Pull back splash shield to gain access to TCM location. (5) Disconnect TCM 60-way connector (Fig. 16). STANDARD PROCEDURE - QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRBIIIt scan tool. This program allows the electronic transaxle system to recalibrate itself. This will provide the best possible transaxle operation. NOTE: The quick learn procedure should be performed if any of the following procedures are performed: • Transaxle Assembly Replacement • Transmission Control Module Replacement • Solenoid/Pressure Switch Assembly Replacement • Clutch Plate and/or Seal Replacement • Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: • The brakes must be applied • The engine speed must be above 500 rpm • The throttle angle (TPS) must be less than 3 degrees • The shift lever position must stay until prompted to shift to overdrive • The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRBIIIt indicates the procedure is complete • The calculated oil temperature must be above 60° and below 200° Fig. 16 Transmission Control Module 60-way Connector 1 - TRANSMISSION CONTROL MODULE (TCM) 2 - 60-WAY CONNECTOR 8E - 32 ELECTRONIC CONTROL MODULES RS TRANSMISSION CONTROL MODULE (Continued) (6) Remove three (3) TCM-to-rail screws and remove TCM from vehicle (Fig. 17). Fig. 18 Transmission Control Module Removal/ Installation Fig. 17 Transmission Control Module Removal/ Installation 1 2 3 4 - SCREW TRANSMISSION CONTROL MODULE (TCM) CLIP LEFT RAIL 1 2 3 4 - SCREW TRANSMISSION CONTROL MODULE (TCM) CLIP LEFT RAIL INSTALLATION NOTE: If transmission control module is being replaced with a new or replacement unit, the Pinion Factor and Quick Learn procedures must be performed. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to 8 ELECTRICAL/ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (1) Install TCM into position (Fig. 18). Install three (3) screws and torque to 3 N·m (30 in. lbs.). (2) Install TCM harness 60–way connector (Fig. 19) and torque to 4 N·m (35 in. lbs.). (3) Install splash shield into position with fasteners. (4) Install left front wheel/tire assembly. (5) Lower vehicle. (6) Connect battery negative cable. (7) If TCM was replaced, reset Pinion Factor and Quick Learn. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE). Fig. 19 Transmission Control Module 60-way Connector 1 - TRANSMISSION CONTROL MODULE (TCM) 2 - 60-WAY CONNECTOR RS MEMORY SEAT/MIRROR MODULE DESCRIPTION Vehicles equipped with the memory seat/mirror option, utilize a memory module located under the drivers front seat. This module is basically wired inline between the power seat switch and the power seat track/adjuster motors, or in-line between the power mirror switch and the power side view mirror(s) motor(s). The MSMM contains a central processing unit that communicates with other modules on the Programmable Communications Interface (PCI) data bus network. The Memory Seat/Mirror Module (MSMM) receives hard wired inputs from the driver power seat switch and the potentiometers on each of the driver side power seat track motors, or from the power mirror switch and the potentiometers on the side view mirror. The MSMM receives messages over the PCI data bus from the Body Control Module (BCM) (memory switch status), the Powertrain Control Module (PCM) (vehicle speed status). The MSMM will prevent the seat memory recall function from being initiated if the driver side seat belt is buckled, if the transmission gear selector lever is not in the Park or Neutral positions, or if the vehicle is moving. For diagnosis of the MSMM or the PCI data bus, a DRB IIIt scan tool and the proper Diagnostic Procedures manual are recommended. The MSMM cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Memory System in the Power Seat or Power Mirror section of this manual for more information on the memory system option. OPERATION When memory system operation is requested (depressing of the memory switch), a resistor multiplexed signal is sent from the memory switch to the body control module (BCM). The body control module will then send the appropriate signals out to the memory/mirror seat module, the memory/mirror seat module then applies the voltage supply to the power seat track or side-view mirror if the proper requirements are met. The vehicle speed must equal zero and the transmission must be in park or neutral in order for the memory system to function. DIAGNOSIS AND TESTING - MEMORY SEAT/MIRROR MODULE Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. If any of the above conditions are present, repair as necessary. If not, use a DRB IIIt scan tool and the proper Diagnostic Procedures Manual to test ELECTRONIC CONTROL MODULES 8E - 33 the memory/mirror seat module. For complete circuit diagrams, refer to Wiring Diagrams. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the driver side front bucket seat retaining nuts from under the vehicle (Refer to 23 BODY/SEATS/SEAT - REMOVAL). (3) Lift the drivers seat up and out of the mounting holes in the floor pan and lay the seat rearward to access the module located under the seat. It is not necessary to disconnect the seat electrical, just use care not to damage the wiring by over-extending. (4) Disconnect the memory/mirror seat module electrical connectors. Depress the retaining tab and pull straight apart. (5) Remove the module retaining bolts and remove the module from the bracket. INSTALLATION (1) Position and install the module retaining bolts. (2) Connect the memory/mirror seat module electrical connectors. (3) Position the drivers seat in the mounting holes in the floor pan. (4) Install the driver side front bucket seat retaining nuts from under the vehicle (Refer to 23 - BODY/ SEATS/SEAT - INSTALLATION). (5) Connect the battery negative cable. SLIDING DOOR CONTROL MODULE DESCRIPTION Vehicles equipped with a power sliding door utilize a sliding door control module. The sliding door control module is located behind the sliding door trim panel in the center of the door, just above the sliding door motor (Fig. 20). This module controls the operation of the door through the Programmable Communication Interface (PCI) J1850 data bus circuit and the Body Control Module. The sliding door control module contains software technology which enables it to detect resistance to door travel and to reverse door travel in order to avoid damage to the door or to avoid possible personal injury if the obstruction is a person. This feature functions in both the opening and closing cycles. If the power sliding door system develops any problems the control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB IIIt is required to read and troubleshoot these trouble codes. The sliding door control module can be 8E - 34 ELECTRONIC CONTROL MODULES RS SLIDING DOOR CONTROL MODULE (Continued) engage the clutch assembly and drive the door into the full open position. If an obstacle is felt during this power open cycle, the module will reverse direction and close the door. This process is also enabled during a power close cycle. This process will repeat three times, and if a fourth obstacle is detected, the door will go into full manual mode. Once the full open position is obtained, a hold open latch assembly mounted full open switch tells the control module that the door has reached the full open position. If the power sliding door system develops any problems the control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB IIIt is required to read and troubleshoot these trouble codes. REMOVAL Fig. 20 Power Side Door Components 1 2 3 4 5 6 7 - SLIDING DOOR CONTROL MODULE MODULE RETAINING SCREW MODULE ELECTRICAL CONNECTORS DOOR MOTOR ASSEMBLY FLEX DRIVE ASSEMBLY DOOR MOTOR RETAINING FASTENERS DOOR MOTOR ELECTRICAL CONNECTOR reflashed if necessary. Refer to the latest Technical Service Bulletin (TSB) Information for any updates. The power door control module is a replaceable component and cannot be repaired, if found to be faulty it must be replaced. Consult your Mopar™ parts catalog for a specific part number. OPERATION The power sliding door control module serves as the main computer for the power sliding side door system. All power door functions are processed through the power door control module and/or the vehicles body control module (BCM). At the start of a power open command, a signal is sent to the BCM and then to the power door control module via the J1850 data bus circuit. This signal, generated by any of the power door command switches, tells the power door control module to activate a power latch release, (1) Disconnect and isolate the negative battery cable. (2) Remove the appropriate door trim panel from the vehicle. Refer to Body for the procedure. (3) Remove the weather shield. Refer to Body for the procedure. (4) Disconnect the power door control module electrical connectors. Slide the red locking tab out (away from module) and depress connector retaining tab, while pulling straight apart. (5) Remove the control module retaining screw (Fig. 20). (6) Remove the module from the vehicle. INSTALLATION (1) Position the control module and install the retaining screw. (2) Connect the control module electrical connectors. Slide the locking tab into the locked position. (3) Install the appropriate door trim panel on the vehicle. Refer to Body for the procedure. (4) Install the weather shield. Refer to Body for the procedure. (5) Connect the negative battery cable. (6) Using an appropriate scan tool, check and erase any power door control module diagnostic trouble codes. (7) Verify power door system operation. Cycle the power door through one complete open and close cycle. ELECTRONIC CONTROL MODULES RG 8Ea - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ENGINE CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 STANDARD PROCEDURE - PCM/ECM/SKIM PROGRAMMING - DIESEL ...............2 REMOVAL .............................4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE CONTROL MODULE DESCRIPTION The ECM is located in the left front corner of the engine compartment attached to the radiator support (Fig. 1). monitoring is called on-board diagnostics. Certain criteria must be met for a diagnostic trouble code to be entered into the ECM memory. The criteria may be a range of: engine rpm, engine temperature, time or other input signals to the ECM. If all of the criteria for monitoring a system or circuit are met, and a problem is sensed, then a DTC will be stored in the ECM memory. It is possible that a DTC for a monitored circuit may not be entered into the ECM memory, even though a malfunction has occurred. This may happen when the monitoring criteria have not been met. The ECM compares input signal voltages from each input device with specifications (the established high and low limits of the input range) that are programmed into it for that device. If the input voltage is not within the specifications and other trouble code criteria are met, a DTC will be stored in the ECM memory. ECM OPERATING MODES As input signals to the ECM change, the ECM adjusts its response to the output devices. For example, the ECM must calculate a different fuel quantity and fuel timing for engine idle condition than it would for a wide open throttle condition. There are several different modes of operation that determine how the ECM responds to the various input signals. Fig. 1 ENGINE CONTROL MODULE LOCATIONTYPICAL 1 2 3 4 5 6 7 - BATTERY IPM (INTEGRATED POWER MODULE) ECM (ENGINE CONTROL MODULE) RETAINING BOLT RADIATOR SUPPORT CLUTCH CABLE BRACKET (LHD) CLUTCH CABLE BRACKET RETAINING BOLT (LHD) OPERATION The ECM has been programmed to monitor different circuits of the diesel fuel injection system. This Ignition Switch On (Engine Off) When the ignition is turned on, the ECM activates the glow plug relay for a time period that is determined by engine coolant temperature, atmospheric temperature and battery voltage. Engine Start-Up Mode The ECM uses the engine temperature sensor and the crankshaft position sensor (engine speed) inputs to determine fuel injection quantity. Normal Driving Modes Engine idle, warm-up, acceleration, deceleration and wide open throttle modes are controlled based on all of the sensor inputs to the ECM. The ECM uses 8Ea - 2 ELECTRONIC CONTROL MODULES RG ENGINE CONTROL MODULE (Continued) these sensor inputs to adjust fuel quantity and fuel injector timing. Limp-In Mode If there is a fault detected with the accelerator pedal position sensor, the ECM will set the engine speed at 1100 RPM. Overspeed Detection Mode If the ECM detects engine RPM that exceeds 5200 RPM, the ECM will set a DTC in memory and illuminate the MIL until the DTC is cleared. After-Run Mode The ECM transfers RAM information to ROM and performs an Input/Output state check. MONITORED CIRCUITS The ECM is able to monitor and identify most driveability related trouble conditions. Some circuits are directly monitored through ECM feedback circuitry. In addition, the ECM monitors the voltage state of some circuits and compares those states with expected values. Other systems are monitored indirectly when the ECM conducts a rationality test to identify problems. Although most subsytems of the engine control module are either directly or indirectly monitored, there may be occasions when diagnostic trouble codes are not immediately identified. For a trouble code to set, a specific set of conditions must occur and unless these conditions occur, a DTC will not set. DIAGNOSTIC TROUBLE CODES Each diagnostic trouble code (DTC) is diagnosed by following a specific procedure. The diagnostic test procedure contains step-by-step instruction for determining the cause of the DTC as well as no trouble code problems. Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information. HARD CODE A DTC that comes back within one cycle of the ignition key is a hard code. This means that the problem is current every time the ECM/SKIM checks that circuit or function. Procedures in this manual verify if the DTC is a hard code at the beginning of each test. When the fault is not a hard code, an intermittent test must be performed. NOTE: If the DRBIIIt displays faults for multiple components (i.e. ECT, VSS, IAT sensors) identify and check the shared circuits for possible problems before continuing (i.e. sensor grounds or 5-volt supply circuits). Refer to the appropriate schematic to identify shared circuits. Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information. INTERMITTENT CODE A DTC that is not current every time the ECM/ SKIM checks the circuit or function is an intermittent code. Most intermittent DTCs are caused by wiring or connector problems. Problems that come and go like this are the most difficult to diagnose; they must be looked for under specific conditions that cause them. NOTE: Electromagnetic (radio) interference can cause an intermittent system malfunction. This interference can interrupt communication between the ignition key transponder and the SKIM. The following checks may assist you in identifying a possible intermittent problem: • Visually inspect the related wire harness connectors. Look for broken, bent, pushed out or corroded terminals. • Visually inspect the related wire harness. Look for chafed, pierced or partially broken wire. • Refer to hotlines or technical service bulletins that may apply. Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information. ECM DIAGNOSTIC TROUBLE CODES IMPORTANT NOTE: Before replacing the ECM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal failures to components (i.e. relays and solenoids) and shorted circuits (i.e. sensor pullups, drivers and ground circuits). These faults are difficult to detect when a double fault has occurred and only one DTC has set. If the DRBIIIt displays faults for multiple components (i.e.VSS, ECT, Batt Temp, etc.) identify and check the shared circuits for possible problems before continuing (i.e. sensor grounds or 5-volt supply circuits). Refer to the appropriate wiring diagrams to identify shared circuits. Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information. STANDARD PROCEDURE - PCM/ECM/SKIM PROGRAMMING - DIESEL NOTE: Before replacing the PCM/ECM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. RG ELECTRONIC CONTROL MODULES 8Ea - 3 ENGINE CONTROL MODULE (Continued) PCM/SKIM PROGRAMMING When a PCM (JTEC) and the SKIM are replaced at the same time perform the following steps in order: (1) Program the new PCM (JTEC) (2) Program the new SKIM (3) Replace all ignition keys and program them to the new SKIM. ECM/SKIM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: (1) Program the new SKIM (2) Program the new ECM (Bosch) PROGRAMMING THE ECM (Bosch) (1) To program the VIN, connect the DRB III and turn the ignition on. (2) Select Engine from the main menu. The DRB III will require the VIN to be entered before continuing. (3) Select ENTER to update the VIN. The DRB III will display the updated VIN. (4) If the engine is equipped with air conditioning, the ECM A/C function must be enabled. Enable the ECM A/C function as follows: • Using the DRB III select ENGINE, MISCELLANEOUS, then ENABLE/DISABLE A/C • Push 1 to enable A/C. DRB III screen should display A/C Activated. PROGRAMMING THE PCM (JTEC) The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB III. Perform the following steps to program the secret key into the PCM. (1) Turn the ignition switch on (transmission in park/neutral). (2) Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. (3) Select PCM REPLACED (GAS ENGINE). (4) Enter secured access mode by entering the vehicle four-digit PIN. (5) Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured 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. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). (6) Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). (7) Press Page Back to get to the Select System menu and select ENGINE, JTEC (diesel only), MISCELLANEOUS, and SRI MEMORY CHECK. (8) The DRB III will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading. Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM (1) Turn the ignition switch on (transmission in park/neutral). (2) Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. (3) Select PCM REPLACED (GAS ENGINE). (4) Program the vehicle four-digit PIN into SKIM. (5) Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. (6) Select YES to update VIN (the SKIM will learn the VIN from the PCM). (7) Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). (8) Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM (1) Turn the ignition switch on park/neutral). (2) Use the DRB III and select SKIM then MISCELLANEOUS. (3) Select PROGRAM IGNITION (4) Enter secured access mode vehicle four-digit PIN. (transmission in THEFT ALARM, KEY’S. by entering the NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the DRB III will display one of the following messages: Programming Not Attempted - The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory. 8Ea - 4 ELECTRONIC CONTROL MODULES RG ENGINE CONTROL MODULE (Continued) (4) Remove ECM upper mounting bolts (Fig. 3). Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: • faulty ignition key transponder • ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done SKIM transponder ID memory is full. (5) Obtain ignition keys to be programmed from customer (8 keys maximum). (6) Using the DRB III, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS. (7) Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. REMOVAL (1) Disconnect negative battery cable. (2) Remove left front headlamp module (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ HEADLAMP UNIT - REMOVAL). (3) Remove lower headlamp assembly mounting bolt (Fig. 2). Fig. 3 ENGINE CONTROL MODULE-UPPER MOUNTING BOLTS 1 2 3 4 5 6 - BATTERY INTEGRATED POWER MODULE ENGINE CONTROL MODULE RADIATOR SUPPORT ECM UPPER MOUNTING BOLTS ECM ELECTRICAL CONNECTORS (5) Lift ECM from radiator support. (6) Disconnect ECM electrical connectors. (7) Separate ECM from mounting bracket. INSTALLATION Fig. 2 ENGINE CONTROL MODULE-LOWER MOUNTING BOLT 1 - ENGINE CONTROL MODULE (ECM) 2 - INTEGRATED POWER MODULE 3 - ECM LOWER MOUNTING BOLT (1) Install ECM on mounting bracket. (2) Connect ECM electrical connectors. (3) Place ECM and bracket assembly in position on radiator support. (4) Install upper and lower mounting bolts. (5) Install left headlamp module (Refer to 8 ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ HEADLAMP UNIT - INSTALLATION). (6) Connect negative battery cable. (7) Program ECM as necessary (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE STANDARD PROCEDURE). IGNITION CONTROL RS 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page IGNITION CONTROL DESCRIPTION - IGNITION SYSTEM . OPERATION - IGNITION SYSTEM . . SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . SPARK PLUG CABLE RESISTANCE SPARK PLUG . . . . . . . . . . . . . . . . FIRING ORDER . . . . . . . . . . . . . . . AUTO SHUT DOWN RELAY DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . CAMSHAFT POSITION SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . REMOVAL - 3.3/3.8L . . . . . . . . . . . INSTALLATION INSTALLATION - 2.4L . . . . . . . . . . INSTALLATION - 3.3/3.8L . . . . . . . . IGNITION COIL DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . .........1 .........1 .. . .. .. . . . . . . . . . . . . . . . . . . . . . . . . .2 .2 .2 .3 .........3 .........3 .........3 .........4 .........4 .........4 .........6 .........6 .........6 .........6 page REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . 7 INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . . 8 KNOCK SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL - 3.8L . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . 8 INSTALLATION - 3.8L . . . . . . . . . . . . . . . . . . . 8 SPARK PLUG DESCRIPTION DESCRIPTION - STANDARD 4 CYLINDER . . . 9 DESCRIPTION - PLATINUM PLUGS . . . . . . . . 9 REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPARK PLUG CABLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 .........7 IGNITION CONTROL DESCRIPTION - IGNITION SYSTEM NOTE: All engines use a fixed ignition timing system. Basic ignition timing is not adjustable. All spark advance is determined by the Powertrain Control Module (PCM). The distributorless ignition system used on these engines is referred to as the Direct Ignition System (DIS). The system’s three main components are the coils, crankshaft position sensor, and camshaft position sensor. The coil on plug ignition system utilizes an ignition coil for every cylinder, it is mounted directly over the each spark plug. OPERATION - IGNITION SYSTEM The crankshaft position sensor and camshaft position sensor are hall effect devices. The camshaft position sensor and crankshaft position sensor generate pulses that are inputs to the PCM. The PCM determines engine position from these sensors. The PCM calculates injector sequence and ignition timing from crankshaft & camshaft position. For a description of both sensors, refer to Camshaft Position Sensor and Crankshaft Position Sensor. 8I - 2 IGNITION CONTROL RS IGNITION CONTROL (Continued) SPECIFICATIONS TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. 2.4L Target Magnet Screw 3 30 2.4L Camshaft Sensor Screw 12.9 115 3.3/3.8L Camshaft Sensor Screw 14.1 125 2.4L Ignition coil bolts 11.8 105 3.3/3.8LIgnition coil bolts 11.8 105 Spark Plugs 17.5 13 Knock Sensor 10 7 SPARK PLUG CABLE RESISTANCE 2.4L CABLE Maximum Resistance #1 22.5K ohms #2 22.8K ohms CABLE Maximum Resistance #3 19.3K ohms 1, 2, 3, & 4 10.8K ohms #4 19.3K ohms #5 13.6K ohms #6 16.4K ohms 3.3/3.8L SPARK PLUG Engine Spark Plug Gap Thread Size 2.4L RE14MCC5 0.048 TO 0.053 14mm (1 in.) reach Engine Spark Plug Gap Thread Size 3.3L RE14PLP5 0.048 TO 0.053 14mm (1 in.) reach 3.8L RE14PLP5 0.048 TO 0.053 14mm (1 in. ) reach IGNITION CONTROL RS 8I - 3 IGNITION CONTROL (Continued) FIRING ORDER AUTO SHUT DOWN RELAY DESCRIPTION The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary OPERATION FIRING ORDER 2.4L The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is used only to sense that the ASD relay is energized. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. When energized, the ASD relay provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), (EGR solenoid and PCV heater if equipped) and also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is a Crankshaft Position sensor signal that exceeds a predetermined value. The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. This test is performed only after the engine has been shut off. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. CAMSHAFT POSITION SENSOR DESCRIPTION Firing Order 1-2-3-4-5-6 3.3/3.8L 1 - Electrical Connector The camshaft position sensorfor the 3.3/3.8L is mounted in the front of the timing case cover (Fig. 6) and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head (Fig. 3). 8I - 4 IGNITION CONTROL RS CAMSHAFT POSITION SENSOR (Continued) OPERATION The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM) (Fig. 1). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Fig. 1 Camshaft Position Sensor 1 - ELECTRICAL CONNECTOR 2 - O-RING 3 - PAPER SPACER When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 2). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on (Fig. 2) represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Fig. 2 Camshaft Sprocket 1 2 3 4 5 6 7 - CAMSHAFT SPROCKET CYL #6 CYL #5 CYL #4 CYL #3 CYL #2 CYL #1 REMOVAL REMOVAL - 2.4L The camshaft position sensor is mounted to the rear of the cylinder head. (1) Remove the negative battery cable. (2) Disconnect electrical connectors from the camshaft position sensor (Fig. 3). (3) Remove camshaft position sensor mounting screws. Remove sensor. (4) Loosen screw attaching target magnet to rear of camshaft and remove magnet (Fig. 4). REMOVAL - 3.3/3.8L (1) Disconnect the negative battery cable. (2) Remove the air box cover and inlet tube (Fig. 5). (3) Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 6). (4) Remove bolt holding sensor. (5) Rotate sensor away from block. IGNITION CONTROL RS CAMSHAFT POSITION SENSOR (Continued) Fig. 3 EGR/CAM SENSOR 2.4L Fig. 5 AIR BOX COVER Fig. 4 Target Magnet Removal/Installation 1 - TARGET MAGNET 2 - MOUNTING BOLT 3 - REAR OF CYLINDER HEAD (6) Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. Fig. 6 CAMSHAFT POSITION SENSOR 8I - 5 8I - 6 IGNITION CONTROL RS CAMSHAFT POSITION SENSOR (Continued) INSTALLATION INSTALLATION - 2.4L The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 7). Fig. 8 Camshaft Position Sensor and Spacer 1 - ELECTRICAL CONNECTOR 2 - O-RING 3 - PAPER SPACER Fig. 7 Target Magnet Installation 1 - LOCATING DOWELS 2 - LOCATING HOLES (2) (1) Install target magnet in end of camshaft. Tighten mounting screw to 3 N·m (30 in. lbs.) torque. Over torqueing could cause cracks in magnet. If magnet cracks replace it. (2) Install camshaft position sensor. Tighten sensor mounting screws to 12.9 N·m (115 in. lbs.) torque. (3) Carefully attach electrical connector to camshaft position sensor. (4) Connect the negative battery cable. INSTALLATION - 3.3/3.8L If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor (Fig. 8). (1) Apply a couple drops of clean engine oil to the O-ring prior to installation. (2) Install sensor in the chain case cover and rotate into position. (3) Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N·m (125 in. lbs.) torque. (4) Connect camshaft position sensor electrical connector to harness connector. (5) Install the air box cover and inlet hose (Fig. 5). (6) Connect the negative battery cable. IGNITION COIL DESCRIPTION The ignition coil assembly consists of 2 or 3 independent coils molded together (Fig. 9) or (Fig. 10). The coil assembly for the 3.3/3.8L is mounted on the intake manifold. The coil assembly for the 2.4L is mounted on the cylinder head cover. Spark plug cables route to each cylinder from the coil. OPERATION The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the other cylinder fires on the exhaust stroke. The Powertrain Control Module (PCM) determines which of the coils to charge and fire at the correct time. The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the magnetic energy in the coil transfers to the secondary causing the spark. The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs. Refer to Auto Shutdown (ASD) Relay—PCM Output, in this section for relay operation. IGNITION CONTROL RS 8I - 7 IGNITION COIL (Continued) (3) Remove coil pack mounting bolts. (4) Remove coil pack and heat shield (Fig. 9). REMOVAL - 3.3/3.8L (1) Disconnect the negative battery cable. (2) Remove the throttle and speed control cables from clip. (3) Remove 2 bolts from the Power steering reservoir to intake manifold. (4) Loosen the lower nut for the power steering reservoir from stud on ignition coil bracket. (5) Reposition the Power steering reservoir (Fig. 11). Fig. 9 IGNITION COIL - 2.4L Fig. 11 IGNITION COIL BRACKET 3.3/3.8L (6) Remove the ignition cables from the ignition coil. (7) Disconnect the electrical connector from the ignition coil. (8) Remove 2 nuts from the ignition coil studs. (9) Remove 2 bolts from ignition coil, remove coil. INSTALLATION Fig. 10 IGNITION COIL - 3.3/3.8L 1 -Ignition Coil REMOVAL REMOVAL - 2.4L The electronic ignition coil pack attaches directly to the valve cover. (1) Diconnect the negative battery cable. (2) Disconnect electrical connector from coil pack INSTALLATION - 2.4L (1) Install ignition coil and heat shield to valve cover and tighten bolts. (2) Connect the electrical connector to the ignition coil. (3) Transfer spark plug cables to new coil pack. The coil pack towers are numbered with the cylinder identification. Be sure the ignition cables are fully seated onto the towers. (4) Connect the negative battery cable. 8I - 8 IGNITION CONTROL RS IGNITION COIL (Continued) INSTALLATION - 3.3/3.8L (1) Install coil over studs on bracket. (2) Install 2 bolts to ignition coil. (3) Install 2 nuts to the ignition coil studs. Tighten nuts and bolts. (4) Connect the electrical connector to the ignition coil. (5) Install the ignition cables to the ignition coil. (6) Reposition the Power steering reservoir. Slide bracket over the mounting stud (Fig. 11). (7) Install 2 bolts to the Power steering reservoir to intake manifold. (8) Tighten the lower nut to stud on ignition coil bracket. (9) Install the throttle and speed control cables to clip. (10) Connect the negative battery cable. 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. REMOVAL REMOVAL - 2.4L KNOCK SENSOR The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). (1) Disconnect electrical connector from knock sensor. (2) Use a crow foot socket to remove the knock sensors. DESCRIPTION REMOVAL - 3.8L The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all 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, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as The knock sensor threads into the side of the cylinder block in the rear. (1) Disconnect the negative battery cable. (2) Raise vehicle and support. (3) On All Wheel Drive vehicles remove the PTU (Power Transfer Unit), refer to the Transmission section for more information. (4) Disconnect electrical connector from knock sensor. (5) Use a crow foot socket to remove the knock sensor. INSTALLATION INSTALLATION - 2.4L The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). (1) Install knock sensor. Tighten knock sensor to 10 N·m (7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. (2) Attach electrical connector to knock sensor. INSTALLATION - 3.8L The knock sensor threads into the side of the cylinder block in the rear. (1) Install knock sensor. Tighten knock sensor to 10 N·m (7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. (2) Attach electrical connector to knock sensor. IGNITION CONTROL RS 8I - 9 KNOCK SENSOR (Continued) spark plug identification and specifications, Refer to the Specifications section. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. When the spark plugs use a single or double platinum tips and they have a recommended service life of 100,000 miles for normal driving conditions per schedule A in this manual. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B in this manual. A thin platinum pad is welded to both or center electrode end(s) as show in (Fig. 13). Extreme care must be used to prevent spark plug cross threading, misgaping (Fig. 14) and ceramic insulator damage during plug removal and installation. Fig. 12 Knock Sensor 1 2 3 4 - GENERATOR INTAKE MANIFOLD KNOCK SENSOR STARTER (3) On All Wheel Drive vehicles install the PTU (Power Transfer Unit) for the rear wheels, refer to the Transmission section for more information. (4) Lower vehicle. (5) Connect the negative cable. SPARK PLUG Fig. 13 Platinum Pads 1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY 2 - PLATINUM SPARK SURFACE DESCRIPTION CAUTION: Cleaning of the platinum plug may damage the platinum tip. DESCRIPTION - STANDARD 4 CYLINDER REMOVAL All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Refer to the Specifications section for gap and type of spark plug. DESCRIPTION - PLATINUM PLUGS The V6 engines use platinum resistor spark plugs. They have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. For When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. Always remove cables by grasping at the boot, rotating the boot 1/2 turn, and pulling straight back in a steady motion. (1) Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. (2) Remove the spark plug using a quality socket with a foam insert. (3) Inspect the spark plug condition. 8I - 10 IGNITION CONTROL RS SPARK PLUG (Continued) SPARK PLUG CABLE DESCRIPTION Fig. 14 Setting Spark Plug Electrode Gap 1 - TAPER GAUGE INSTALLATION When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. (1) To avoid cross threading, start the spark plug into the cylinder head by hand. (2) Tighten spark plugs to 17.5 N·m (13 ft. lbs.) torque. (3) Install spark plug cables over spark plugs. A click will be heard and felt when the cable properly attaches to the spark plug. Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature silicone materials. All spark plug cable leads are properly identified with cylinder numbers. The inside of most the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. REMOVAL Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. Remove spark plug cable from coil first. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. INSTALLATION Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube, then connect the other end to coil pack. IGNITION CONTROL RG 8Ia - 1 IGNITION CONTROL TABLE OF CONTENTS page GLOW PLUG DESCRIPTION . . OPERATION . . . . GLOW PLUG RELAY DESCRIPTION . . OPERATION . . . . ........................1 ........................1 ........................1 ........................1 page CAMSHAFT POSITION SENSOR DESCRIPTION . . . . . . . . . . . OPERATION . . . . . . . . . . . . . REMOVAL .............. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 .2 .2 .2 GLOW PLUG GLOW PLUG RELAY DESCRIPTION DESCRIPTION Glow plugs are used to help start a cold or cool engine (Fig. 1). The glow plugs will heat up and glow to heat the combustion chamber of each cylinder. An individual glow plug is used for each cylinder. Each glow plug is threaded into the left side of the cylinder head below the cylinder head cover/intake manifold. There are two glow plug relays. These relays are located in the Power Distribution Center (PDC) in the engine compartment (Fig. 2). Fig. 2 RELAY LOCATIONS Fig. 1 GLOW PLUG OPERATION Each glow plug will momentarily draw approximately 25 amps of electrical current during the initial key “ON” cycle. This is on a cold or cool engine. After heating the current draw will drop to approximately 9–12 amps per plug. Total momentary cuurent draw for all four glow plugs is approximately 100 amps on a cold engine dropping to a total of approximately 40 amps after the plugs are heated. Electrical operation of the glow plugs is controlled by two glow plug relays. Each glow plug relay controls two glow plugs. Refer to glow plug relays for more information. 1 2 3 4 5 6 - GLOW PLUG RELAY RADIATOR SUPPORT CHARGE AIR COOLER OUTLET HOSE COOLING FAN RELAY UPPER RADIATOR HOSE EGR SOLENOID OPERATION When the ignition (key) switch is place in the ON position, a signal is sent to the ECM relating current engine coolant temperature. This signal is sent from the engine coolant temperature sensor. After receiving this signal, the ECM will determine if, when and for how long of a period the glow plug relays should be activated. This is done before, during and after the engine is started. Whenever the glow plug relays are activated, it will control the 12 volt 100 amp circuit for the operation of the four glow plugs. Each relay control two glow plugs. 8Ia - 2 IGNITION CONTROL RG GLOW PLUG RELAY (Continued) The Glow Plug lamp is tied to this circuit. Lamp operation is also controlled by the ECM. With a cold engine, the glow plug relays and glow plugs may be activated for a maximum time of 200 seconds. Refer to the following Glow Plug Control chart for a temperature/time comparison of the glow plug relay operation. In this chart, Pre-Heat and Post-Heat times are mentioned. Pre-Heat is the amount of time the glow plug relay control circuit is activated when the ignition (key) is switched ON, without the engine running. Post-Heat is the amount of time the glow plug relay control circuit is activated after the engine is operated. The Glow Plug lamp will not be activated during the post-heat cycle. Engine Coolant Temperature 9Key ON9 Wait-To Start Lamp 9ON9 (Seconds) Pre-Heat Cycle (Glow Plugs On Seconds) Post-Heat Cycle (Seconds) -30C 20 SEC. 35 SEC. 200 SEC. -10C 8 SEC. 23 SEC. 180 SEC. +10C 6 SEC. 21 SEC. 160 SEC. +30C 5 SEC. 20 SEC. 140 SEC. +40C 4 SEC. 19 SEC. 70 SEC. +70C 1 SEC. 16 SEC. 20 SEC. OPERATION The CMP sensor is a hall effect switch. A tooth made of a ferromagnetic material is attached to the camshaft. When this tooth passes the CMP sensor an lectronic signal is created. This signal is then sent to the engine control module (ECM). This signal is used by the ECM to determine which cylinder has just entered its compression phase. REMOVAL (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL). (3) Disconnect camshaft position sensor electrical connector (Fig. 4). CAMSHAFT POSITION SENSOR DESCRIPTION The camshaft position (CMP) sensor is mounted in the top of cylinder head cover/intake manifold at the rear of the engine. The CMP sensor is a hall effect device (Fig. 3). Fig. 4 CAMSHAFT POSITION SENSOR LOCATION 1 2 3 4 5 - CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR ELCTRICAL SENSOR FUEL INJECTOR CYLINDER HEAD COVER OIL SEPARATOR (4) Remove sensor retaining bolt and remove sensor from cylinder head cover. INSTALLATION (1) Lubricate O-ring and install sensor in cylinder head cover. Torque retaining bolt to 5.4 N·m. (2) Connect camshaft position sensor electrical connector. (3) Install engine cover (Refer to 9 - ENGINE COVER - INSTALLATION). (4) Connect negative battery cable. Fig. 3 CAMSHAFT POSITION SENSOR HEATING & AIR CONDITIONING RS 24 - 1 HEATING & AIR CONDITIONING TABLE OF CONTENTS page HEATING & AIR CONDITIONING DESCRIPTION DESCRIPTION - SINGLE ZONE ........ DESCRIPTION - DUAL ZONE . . . . . . . . . . DESCRIPTION - MANUAL THREE ZONE . . DESCRIPTION - THREE ZONE AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . OPERATION OPERATION - DUAL ZONE . . . . . . . . . . . . OPERATION - MANUAL THREE ZONE . . . OPERATION - THREE ZONE ATC . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - A/C COOL DOWN TEST . . . . . . . . . . . . . . . . . . . . . . . ...1 ...1 ...1 ...2 ...3 ...3 ...4 page DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST . . . . . . . . . . . . . . . . . . 5 DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST . . . . . . . . . . . . . . . . . . 6 SPECIFICATIONS - HEATER-A/C SYSTEM . . . . . 7 CONTROLS - FRONT . . . . . . . . . . . . . . . . . . . . . . 8 CONTROLS - REAR . . . . . . . . . . . . . . . . . . . . . . 29 DISTRIBUTION - FRONT . . . . . . . . . . . . . . . . . . . 39 DISTRIBUTION - REAR . . . . . . . . . . . . . . . . . . . . 51 PLUMBING - FRONT . . . . . . . . . . . . . . . . . . . . . 59 PLUMBING - REAR . . . . . . . . . . . . . . . . . . . . . . 97 DIESEL SUPPLEMENTAL HEATER - DCHA BUX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 ...5 HEATING & AIR CONDITIONING DESCRIPTION DESCRIPTION - SINGLE ZONE A single zone heating and air conditioning system allows one temperature setting for the entire vehicle. The full range of temperatures that the system can produce are available by rotating the temperature control located in control panel. The control panel and integral computer is mounted in the instrument panel. DESCRIPTION - DUAL ZONE A manual Dual Zone Heating and Air Conditioning system allows completely independent side-to-side tempeture control of the discharge air. The Dual Zone Heating and Air Conditioning system includes a dust and odor air filter. The filter element is the same size as the air conditioning evaporator to ensure ample capacity. A door at the base of the heating and air conditioning housing below the glove box provides easy access to the filter element. The control panel and integral computer is located in the instrument panel. The instrument panel mounted control and integral computer contains: • a power button which allows the system to be completely turned off. Contains an LED that illuminates to show when the function is operational. • rear window defogger on/off switch. Contains an LED that illuminates to show when the function is operational. • slide controls for completely independent side-toside temperature control of the discharged air. The full range of temperature that the system can produce in any mode is available on either side of the vehicle by independently positioning the slide controls on the instrument panel. • air recirculation on/off switch. The Recirculate button contains an LED that illuminates to show when the function is in operation. • air conditioning on/off switch. The Snowflake button contains an LED that illuminates to shown when the function is in operation. • rotary knob for fan speed selection. • a rotary knob for mode control. DESCRIPTION - MANUAL THREE ZONE The fully adjustable Three-Zone front and rear heating and air conditioning system allows intermediate seat passengers the ability to regulate air temperature as well as fan speed. All controls are identified by ISO graphic symbols. The Three Zone Heating and Air Conditioning system includes a dust and odor air filter. The filter element is the same size as the air conditioning evaporator to ensure ample capacity. A door at the base of the heating and air conditioning housing below the glove box provides easy access to the filter element. 24 - 2 HEATING & AIR CONDITIONING RS HEATING & AIR CONDITIONING (Continued) FRONT CONTROL PANEL The front control panel and integral computer is mounted in the instrument panel. The instrument panel mounted control and integral computer contains: • a power button which allows the system to be completely turned off. • rear window defogger on/off switch. • slide controls for completely independent side-toside temperature control of the discharge air. The full range of temperature that the system can produce in any mode is available on either side of the vehicle by independently positioning the slide controls on the instrument panel. • air recirculation button. The Recirculate button contains an LED that illuminates to show when the function is in operation. • an air conditioning button that allows the compressor to be turned on/off. The Snowflake button contains an LED that illuminates to shown when the function is in operation. • rotary knobs for front and rear fan speed selection. • a rotary knob for mode control. REAR CONTROL PANEL A rear control panel centrally mounted on the headliner has a rotary adjustment for temperature and fan speed control of the rear unit by intermediate seat passengers when the front control rear knob is set to the rear position. DESCRIPTION - THREE ZONE AUTOMATIC TEMPERATURE CONTROL The Three-Zone Automatic Temperature Control (ATC) allows occupants to select a comfort temperature, which is the perceived temperature level not the actual passenger compartment air temperature. The Three Zone Automatic Temperature Control system includes a dust and odor air filter. The filter element is the same size as the air conditioning evaporator to ensure ample capacity. A door at the base of the heater and air conditioning housing below the glove box provides easy access to the filter element. The ATC computer utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the ATC computer allow it to control electronic functions and features of the ATC system. The inputs to the ATC computer are: • Vehicle Speed/Engine RPM – The ATC computer monitors engine RPM, vehicle speed and Manifold Absolute Pressure information from the PCM. • Coolant Temperature – ATC computer monitors Coolant temperature received from the PCM and converts it to degrees Fahrenheit. • Ambient Temperature – ATC computer monitors Ambient temperature from the Compass Mini Trip Computer (CMTC) and converts it to degrees Fahrenheit. • Engine Miscellaneous Sensor Status – ATC computer monitors A/C disable information from the PCM. • Refrigerant Pressure – ATC computer monitors Barometric Pressure, Intake Air Temperature, High Side Pressure and Methanol Content as broadcast by the PCM. • Door Ajar Status – The ATC computer monitors Driver Front Door, Passenger Front Door, Left Rear Door, Right Rear Door and Liftgate ajar information, as identified by the Body Control Module (BCM), to determine if all in-car temperatures should be maintained. • Dimming – The ATC computer monitors dimming status from the BCM to determine the required level of brightness and will dim accordingly. • Vehicle Odometer – The ATC computer monitors the vehicle odometer information from the BCM to prevent flashing the VF tube icons if the manual motor calibration or manual cool down tests have failed. Flashing of the display icons will cease when the vehicle odometer is greater than 3 miles. • English Metric – The ATC computer monitors the English/Metric information broadcast by the CMTC. The set temp displays for both the front and rear control heads will be set accordingly. • Vehicle Identification Number – The ATC computer monitors the last eight characters of the VIN broadcast by the PCM and compares it to the information stored in EEPROM. If it is different, the new number will be stored over the old one and a motor calibration shall be initiated. • A/C System Information – The ATC computer will send a message for Evaporator Temperature too Low, Fan Blower Relay status, Evaporator Sensor Failure, Rear Window Defogger Relay and A/C Select. FRONT CONTROL PANEL The front control panel and integral computer is mounted in the instrument panel. The instrument panel mounted control and integral computer contains: • A power button which allows the system to be completely turned off. The display is blank when the system is off. • Three rocker switches that select comfort temperatures from 15° to 30° C (59° to 85° F), which are shown in the vacuum-fluorescent digital control display. If the set temp is 59 and the down button is RS HEATING & AIR CONDITIONING 24 - 3 HEATING & AIR CONDITIONING (Continued) pressed, the set temp value will become 55 but the display will show LO. If the set temp is 85 and the up button is pressed, the set temp value will become 90 but the display will show HIGH. Temperatures can be displayed in either metric or Fahrenheit, which is controlled from the overhead console. • A rocker switch that selects a cool-down rate. LO-AUTO or HI-AUTO are displayed when the system is in automatic operation. • A defroster button which turns on the defroster independently during full automatic control. A defroster symbol illuminates in the display when the button is pressed. • Air recirculation button. A Recirculation symbol appears in the display when the button is pressed, or when the system exceeds 80 percent circulated air under automatic control due to high air conditioning demand. • Rear window defogger on/off switch. A graphic symbol shows when the defroster is on. • An air conditioning button that allows the compressor to be turned off. A Snowflake symbol is illuminated when air conditioning is on, whether under manual or automatic control. • Rotary knob for front fan speed selection can override the automatic controls. LEDs surrounding the knob show the current setting. • Rotary knob for control of the Rear system. • A rotary knob for mode control can override the automatic controls. LEDs surrounding the knob show the current setting. • Computer logic remembers the settings of the controls when the ignition is turned off and retains those settings after a restart. If the system is off when the ignition is turned off it will be off when the engine is restarted, etc. • Computer logic provides variable air recirculation under high temperature and humidity conditions. Because recirculation is generally accompanied by increased fan noise, the proportion of recirculated to outside air gradually approaches full recirculation over a broad temperature range. • A graphic symbol of the windshield that illuminates when the windshield wiper deicer is active. REAR CONTROL PANEL A rear control panel centrally mounted on the headliner includes a vacuum-flourescent digital display, a rocker control for temperature and rotary controls for adjustment of mode and fan speed control of the rear unit by intermediate seat passengers. OPERATION OPERATION - DUAL ZONE • The mode control knob enables continously variable proportioning of air flow between modes but has detents adjacent to each icon. • The blower control provides five separate speeds. • When the fan is off, the HVAC computer closes the recirculation door to prevent outside air from entering the passenger compartment. • Interior air may be recirculated to speed up heating or cooling in all modes except defrost and mix by pressing the Recirculate button on the control panel. • To reduce humidity for rapid defogging the A/C compressor runs automatically in modes from “mix’ to full defrost when outside temperatures are above freezing. • Air conditioning is available in any mode by pressing the snowflake, A/C on/off, button. OPERATION - MANUAL THREE ZONE FRONT CONTROL PANEL • Primary control of the rear compartment unit is on the instrument panel. This control allows the driver to set the rear compartment fan speed, to turn the rear unit off, or to give control to the intermediate seat occupants by switching to the REAR position. When the rear unit is controlled from the instrument panel, rear air temperature is based on the driver-side temperature control position, and the mode (floor or overhead air) is based on the front control’s mode position. • The mode control knob enables continously variable proportioning of air flow between modes but has detents adjacent to each icon. • The blower control provides five separate speeds and Off. When the fan is off, the HVAC computer closes the recirculation door to prevent outside air from entering the passenger compartment. • Interior air may be recirculated to speed up heating or cooling in all modes exccept defrost and mix by pressing the Recirculate button on the control panel. • To reduce humidity for rapid defogging the A/C compressor runs automatically in modes from “mix’ to full defrost when outside temperatures are above freezing. • Air conditioning is available in any mode by pressing the snowflake, A/C on/off, button. 24 - 4 HEATING & AIR CONDITIONING RS HEATING & AIR CONDITIONING (Continued) REAR CONTROL PANEL Comfort temperature or perceived temperature is affected by air flow, sun impinging on exposed skin, etc. The air temperature may be higher or lower than the comfort temperature. Three infrared sensors, two in the instrument panel center stack, and one in the overhead-mounted rear control panel, independently measure the temperature of the driver, front passenger, and rear compartment occupants to determine their comfort level relative to the selected comfort temperature. The HVAC computer in the control module adjusts the air flow rate and temperature to maintain the customer-perceived comfort temperature. The air temperature in the passenger compartment at any time may be slightly higher or lower than the comfort temperature. For instance, on sunny summer days the air flow will probably be cooler than the comfort temperature; on cold or cloudy days and at night it will probably be slightly warmer. Infrared Three-Zone Temperature Control provides side-to-side and front-to-rear variation in comfort temperature settings. The Infrared ThreeZone Automatic Temperature Control fan provides a continuously variable air flow rate to meet occupant comfort requirements. Defogger and side view mirror (if equipped) circuitry. The defogger function will be active for 10 minutes and can be turned off by a switch press. The defogger will function while the control is in the OFF mode. • FAN/MODE – The Fan and Mode knobs have 17 manual selectable positions. Manually changing either of the rotary knobs for mode or fan speed settings makes control of that function alone manual for as long as the ignition is on. If only one is changed manually, the other remains under automatic control. Pressing the HI-AUTO/LO-AUTO rocker switch restores full automatic control. • REAR CONTROL – When the Rear System control knob is moved to the OFF position, there will be a delay of approximately 1 second before the system actually turns off. This delay is to prevent an undesired blower dropout if the knob is moved through OFF to the other selections. • BLOWER DELAY TIMER – The word DELAY is displayed at start-up to signify that the system is waiting so that cold air will not be blowing. This tells the operator that it is unnecessary to turn the system off, raise the temperature setting or turn the fan speed setting down to prevent cold air from blowing. A countdown in minutes and seconds until the engine is warm enough to begin delivering heat to the passengers alternates with the DELAY message at 25 second intervals. This countdown is based on actual measurement of the rate of engine coolant temperature change. During the delay time, Defrost mode is selected and the fan operates at a low speed to keep the windshield fog free. FRONT CONTROL PANEL REAR CONTROL PANEL With the rear control active, temperature selection dictates indirectly the mode (floor or overhead air) of the rear unit: a low temperature setting directs flow to the overhead outlets and a high temperature setting to the floor. OPERATION - THREE ZONE ATC • AUTO HI/LO – This system features two sets of automatic control logic that allow either a rapid cooldown rate or a somewhat slower cool-down rate with less fan noise. HI-AUTO controls the system to reach its assigned temperature quickly with a higher fan speed. LO-AUTO controls the system to reach its assigned temperature somewhat slower with less fan noise. Both modes will automatically engage auto recirculation. • DE-FROST – The front de-frost function is active when the rear window defogger function is active or when the defog/defrost mode is selected. • RECIRC – The RECIRC button will close the air inlet door. If the system is in auto recirc (indicator being displayed automatically), pressing the manual recirc button will disable the auto recirc function until one of the auto keys are pressed or the ignition is cycled. If Auto HI/LO is pressed while manual recirc is active, manual recirc will be deactivated. • REAR WINDOW DEFOGGER – Pushing the button sends a PCI bus message to the Intelligent Power Module which controls the Rear Window Primary control of the rear compartment unit is in the instrument panel center stack. The rear unit control knob there allows the driver to turn the rear unit off, allow control by the intermediate seat occupants by switching to the REAR position, or provide fully automatic control based on the temperature setting shown on the front control display. • REAR CONTROL – Selecting automatic control of the rear unit at the instrument panel, illuminates a Locked Padlock in the rear control panel display. Selecting REAR activates the rear control panel and the Padlock then appears unlocked. • FAN KNOB – The rear fan control has Off and AUTO positions and a range of manual speed settings that override the AUTO setting. • MODE KNOB – The mode control allows intermediate seat occupants to manually override the automatic mode and select any balance of air flow between overhead and floor outlets from full overhead to full floor. • SET TEMP – The rear set temp control will operate identical to the front controls. If the front RS HEATING & AIR CONDITIONING 24 - 5 HEATING & AIR CONDITIONING (Continued) control rear set temp button is pressed simultaneously with the rear control head, then the front control head press events shall have priority, i.e. if the front user presses Rear Set Temp down and the rear user presses Set Temp up, then the rear set temp will decrease. perature reaching 20° F less than the evaporator initial temperature, then the cool down test has been failed and further A/C system diagnosis is required. If the test is failed, the snowflake icon and the DELAY text will continue to blink across ignition cycles until the vehicle has been driven for greater than (8 miles). DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST DIAGNOSIS AND TESTING - A/C COOL DOWN TEST The heater-A/C control module can perform an A/C cool down test, which is a test performed during the manufacturing process to confirm that the air conditioning system is performing satisfactorily. This test can also provide a quick confirmation of air conditioning system performance to the service technician. If the test is completed satisfactorily, no further service is required. If the test is failed, proceed to the A/C Performance Test to confirm the a/c system is operating properly, or use a DRBIIIt scan tool to diagnose the A/C system control and distribution systems. Refer to the appropriate diagnostic information. MANUAL TEMPERATURE CONTROL The front blower speed and rear blower speed (if equipped with rear HVAC) must be set to High and the evaporator temperature sensor must be greater than 55° F or the test will fail immediately. The test is activated by depressing the A/C and PWR buttons simultaneously and holding them depressed for no less than five seconds. The PWR and A/C LEDs will blink on and off until the test is complete. If the LEDs stop blinking before two minutes, then the cool down test has been completed successfully. If the two minutes expire without the expansion valve temperature reaching 20° F less than the outside air temperature, then the cool down test has been failed and further A/C system diagnosis is required. If the test is failed, the LEDs will continue to blink until the vehicle has been driven for greater than (8 miles). AUTOMATIC TEMPERATURE CONTROL The ambient air temperature in the room where the vehicle will be tested must be a minimum of 21° C (70°F) for this test. The test is activated by depressing the A/C and PWR buttons simultaneously and holding them depressed for no less than four seconds. The snowflake icon and the DELAY text in the ATC display will blink on and off alternately until the test is complete. If the snowflake icon and the DELAY text stop blinking before two minutes, then the cool down test has been completed successfully. If the two minutes expire without the evaporator tem- An air conditioning performance test is the best way to determine whether the system is performing up to standard. This test also provides valuable clues as to the possible cause of trouble with the air conditioning system. The ambient air temperature in the location where the vehicle will be tested must be a minimum of 21° C (70°F) for this test. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. (1) Connect a tachometer to monitor the engine speed. (2) Remove the caps from the refrigerant system service ports and attach a manifold gauge set to monitor the refrigerant system pressures. (3) Set the heater-air conditioner controls so that the compressor is engaged, the air within the vehicle is being recirculated, the output air is directed through the panel outlets, the temperature control is in the full cool position, and the blower motor is operating at its highest speed. (4) Start the engine and allow the engine to operate for about five minutes or until it reaches normal operating temperature. Then hold the engine speed at 1000 rpm with the compressor clutch engaged. If the compressor clutch does not engage, proceed with diagnosis of the compressor clutch coil. (Refer to 24 HEATING & AIR CONDITIONING/CONTROLS FRONT/COMPRESSOR CLUTCH COIL - DIAGNOSIS AND TESTING). (5) Close all the vehicle windows and doors. (6) Insert a thermometer in the left center panel outlet and operate the engine for five minutes. 24 - 6 HEATING & AIR CONDITIONING RS HEATING & AIR CONDITIONING (Continued) (7) With the compressor clutch engaged, record the left center panel outlet discharge air temperature, the discharge pressure (high side service port), and the suction pressure (low side service port). The compressor clutch may cycle, depending upon the ambient temperature and humidity. If the clutch cycles, use the readings obtained before the clutch disengaged. (8) Compare the discharge air temperature reading to the Performance Temperature and Pressure chart. If the temperature reading is high, check the refrigerant system for leaks and proper refrigerant charge level. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT - DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL). Performance Temperature and Pressure Ambient Temperature Left Center Panel Outlet Discharge Air Temperature Discharge Pressure (High Side Service Port) Suction Pressure (Low Side Service Port) 21° C (70° F) 27° C (80° F) 32° C (90° F) 38° C (100° F) 43° C (110° F) 1 to 8° C (34 to 46° F) 3 to 9° C (37 to 49° F) 4 to 10°C (39 to 50° F) 6 to 11°C (43 to 52° F) 7 to 18° C (45 to 65° F) 1034 to 1724 kPa (150 to 250 psi) 1517 to 2275 kPa (220 to 330 psi) 1999 to 2620 kPa (290 to 380 psi) 2068 to 2965 kPa (300 to 430 psi) 2275 to 3421 kPa (330 to 450 psi) 103 to 207 kPa (15 to 30 psi) 117 to 221 kPa (17 to 32 psi) 138 to 241 kPa (20 to 35 psi) 172 to 269 kPa (25 to 39 psi) 207 to 345 kPa (30 to 50 psi) DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST PRE-DIAGNOSTIC PREPARATIONS WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). Check the coolant level, drive belt tension, radiator air flow, and cooling fan operation. Start the engine and allow it to warm up to normal temperature. MAXIMUM HEATER OUTPUT: TEST AND ACTION Engine coolant is provided to the heater system by two 16 mm (5/8 inch inside diameter) heater hoses. With the engine idling at normal running temperature, set the heater-A/C controls as follows. Temperature control to full Heat, Mode control to Floor, Blower control to the highest speed setting. Using a test thermometer, check the air temperature coming from the center floor outlets and compare this reading to the Temperature Reference table. TEMPERATURE REFERENCE AMBIENT TEMPERATURE CELSIUS MINIMUM FLOOR OUTLET TEMPERATURE FAHRENHEIT CELSIUS FAHRENHEIT 15.5° 60° 62.2° 144° 21.1° 70° 63.8° 147° 26.6° 80° 65.5° 150° 32.2° 90° 67.2° 153° If the floor outlet air temperature is insufficient, check that the cooling system is operating to specifications. (Refer to 7 - COOLING/ENGINE - DIAGNOSIS AND TESTING). Both heater hoses should be HOT to the touch (the coolant return hose should be slightly cooler than the supply hose). If the coolant return hose is much cooler than the supply hose, locate and repair the engine coolant flow obstruction in heater system. POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW • Pinched or kinked heater hoses. • Improper heater hose routing. • Plugged heater hoses or supply and return ports at cooling system connections. • Plugged heater core. • Air locked heater core. • Restrictor in backwards. HEATING & AIR CONDITIONING RS 24 - 7 HEATING & AIR CONDITIONING (Continued) If coolant flow is verified and the heater floor outlet temperature is insufficient, a mechanical problem may exist. POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT • Obstructed cowl air intake. • Obstructed heater system outlets. • Blend-air door not functioning properly. TEMPERATURE CONTROL If heater floor outlet temperature cannot be adjusted with the heater-A/C control temperature control lever, one of the following could require service: • Blend-air door binding. • Faulty blend-air door motor. • Improper engine coolant temperature. • Faulty heater-A/C control. SPECIFICATIONS - HEATER-A/C SYSTEM ITEM DESCRIPTION NOTES Vehicle RS - Caravan, Town & Country, Voyager System R134a with expansion valve(s) Compressor Nippondenso - 10S20 ND-8 PAG Oil Freeze–up Control evaporator temperature sensor expansion valve mounted - input to heater-A/C control module Low PSI Control High PSI Control liquid line mounted - input to Powertrain Control Module (PCM) - PCM opens compressor clutch relay < 29.4 psi pressure transducer liquid line mounted - input to PCM - PCM opens compressor clutch relay > 450 psi pressure relief valve compressor mounted - opens > 495 psi single zone, dual zone, and three zone Manual Temperature Control (MTC) - or three zone Automatic Temperature Control (ATC) PCI data bus messaging - ATC uses three infrared temperature sensors - two front/one rear Mode Door electric actuator Control head driven Blend Air Door electric actuator Fresh/Recirc Door electric actuator Blower Motor control head switch resistor and relay with MTC, power module and relay with ATC Cooling Fans pulse width modulated variable speed PCM control through solid state fan relay Clutch Control PCM PCM control through compressor clutch relay Clutch Coil Draw 2.2 amps @ 12V ± 0.5amps@ 70° F Compressor Clutch Air Gap 0.0209 - 0.0359 Diagnostics DRBIIIT scan tool Control Head Clutch 24 - 8 CONTROLS - FRONT RS CONTROLS - FRONT TABLE OF CONTENTS page page A/C HEATER CONTROL STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION ................8 REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A/C PRESSURE TRANSDUCER DESCRIPTION - A/C PRESSURE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 BLEND DOOR ACTUATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 BLOWER MOTOR RELAY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DIAGNOSIS AND TESTING - BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 BLOWER MOTOR RESISTOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 COMPRESSOR CLUTCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 STANDARD PROCEDURE STANDARD PROCEDURE - COMPRESSOR CLUTCH AIR GAP . . . . . . . . . . . . . . . . . . . . . 17 STANDARD PROCEDURE - COMPRESSOR CLUTCH BREAK-IN . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION - COMPRESSOR CLUTCH/COIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR CLUTCH COIL DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH COIL . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR CLUTCH RELAY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH RELAY .................... REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . EVAPORATOR TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . INFRARED TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . MODE DOOR ACTUATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . POWER MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . RECIRCULATION DOOR ACTUATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . A/C HEATER CONTROL (1) Turn the ignition switch to the On position. (2) Simultaneously depress and hold the Power and Recirculation buttons on the heater-A/C control for at least five seconds. The manual heater-A/C control power Light Emitting Diode (LED) and Recirculation LED, or the Automatic Temperature Control (ATC) heater-A/C control Delay and Recirculation graphics will begin to flash when the calibration procedure has begun. STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION The heater-A/C control module must be recalibrated each time an actuator motor or the control module is replaced. If the vehicle is so equipped, the calibration procedure also includes rear HVAC positions for each actuator motor. . . 17 . . 17 . 18 . . 19 . . 20 . . 21 . . 21 . . 22 . . 22 . . 22 . . . . . 22 . 23 . 23 . 23 . . 24 . . 24 . . . . . 24 . 25 . 25 . 25 . . . . . 26 . 26 . 26 . 27 . . . . . 27 . 27 . 28 . 28 CONTROLS - FRONT RS 24 - 9 A/C HEATER CONTROL (Continued) (3) The calibration procedure should take less than two minutes to complete for the manual heater-A/C control, and less than twenty seconds for the ATC heater-A/C control. When the LEDs or graphics stop flashing, the calibration procedure is complete. (4) If the LEDs or graphics continue to flash beyond the normal three minute (manual) or twenty second (ATC) calibration time, it indicates that the heater-A/C control has detected a failure and a Diagnostic Trouble Code (DTC) has been set. Use a DRBIIIt scan tool to perform further diagnosis. Refer to the appropriate diagnostic information. The LEDs or graphics will continue to flash even after the ignition switch is cycled Off and On, until a successful calibration is completed or until the vehicle has been driven about 13 kilometers (8 miles). 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 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. (1) Disconnect and isolate the battery negative cable. (2) Remove the center bezel from the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - REMOVAL). (3) Place the instrument panel center bezel unit face down on a suitable work surface. Take the proper precautions to protect the center bezel from cosmetic damage. (4) If the vehicle is equipped with the optional Automatic Temperature Control (ATC) system, disconnect the infrared sensor jumper harness connector from the receptacle on the back of the heater-A/C control (Fig. 1). (5) Remove the six screws that secure the heaterA/C control to the back of the instrument panel center bezel. (6) Remove the heater-A/C control from the instrument panel center bezel. Fig. 1 Heater-A/C Control 1 - INFRARED SENSOR JUMPER CONNECTOR (ATC ONLY) 2 - INFRARED SENSOR JUMPER HARNESS (ATC ONLY) 3 - HEATER-A/C CONTROL 4 - SCREW (6) 5- INSTRUMENT PANEL CENTER BEZEL INSTALLATION 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 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. (1) Position the heater-A/C control onto the back of instrument panel center bezel. (2) Install and tighten the six screws that secure the heater-A/C control to the back of the instrument panel center bezel. Tighten the screws to 2 N·m (17 in. lbs.). (3) If the vehicle is equipped with the optional ATC system, reconnect the infrared sensor jumper harness connector to the receptacle on the back of the heater-A/C control. (4) Reinstall the center bezel onto the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - INSTALLATION). (5) Reconnect the battery negative cable. 24 - 10 CONTROLS - FRONT A/C PRESSURE TRANSDUCER DESCRIPTION - A/C PRESSURE TRANSDUCER RS and other sensor inputs by controlling the operation of the air conditioning compressor clutch and the radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage. The A/C pressure transducer input to the PCM will also prevent the air conditioning compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The Schrader-type valve in the liquid line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the system. The A/C pressure transducer is diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER Fig. 2 A/C Pressure Transducer 1 2 3 4 5 6 - RIGHT FRONT STRUT TOWER - CONNECTOR - A/C PRESSURE TRANSDUCER - RIGHT WIPER MODULE DRAIN TUBE - HIGH SIDE SERVICE PORT - LIQUID LINE The A/C pressure transducer (Fig. 2) is a switch that is installed on a fitting located on the refrigerant liquid line between the filter-drier and the expansion valve in the right rear corner of the engine compartment. An internally threaded hex fitting on the transducer connects it to the externally threaded Schrader-type fitting on the liquid line. A rubber O-ring seals the connection between the transducer and the liquid line fitting. Three terminals within a molded plastic connector receptacle on the top of the transducer connect it to the vehicle electrical system through a take out and connector of the headlamp and dash wire harness. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it musty be replaced. The A/C pressure transducer is tested using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. Before testing the A/C pressure transducer, be certain that the transducer wire harness connection is clean of corrosion and properly connected. For the air conditioning system to operate, an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicate a low or high refrigerant system pressure condition to the Powertrain Control Module (PCM). The PCM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the compressor. Refer to the A/C Pressure Transducer Voltage table for the possible condition indicated by the transducer voltage readings. A/C PRESSURE TRANSDUCER VOLTAGE VOLTAGE 0.0 1. NO SENSOR SUPPLY VOLTAGE FROM PCM. 2. SHORTED SENSOR CIRCUIT. 3. FAULTY TRANSDUCER. 0.150 TO 0.450 1. AMBIENT TEMPERATURE BELOW 10° C (50° F). 2. LOW REFRIGERANT SYSTEM PRESSURE. 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 liquid line. The transducer will change its internal resistance in response to the pressures it monitors. The Powertrain Control Module (PCM) provides a five volt reference signal and a sensor ground to the transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM is programmed to respond to this POSSIBLE INDICATION 0.451 TO 4.519 1. NORMAL REFRIGERANT SYSTEM PRESSURE. 4.520 TO 4.850 1. HIGH REFRIGERANT SYSTEM PRESSURE. 5.0 1. OPEN SENSOR CIRCUIT. 2. FAULTY TRANSDUCER. CONTROLS - FRONT RS 24 - 11 A/C PRESSURE TRANSDUCER (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Disconnect the headlamp and dash wire harness connector for the A/C pressure transducer from the transducer connector receptacle (Fig. 3). Fig. 3 A/C Pressure Transducer 1 2 3 4 5 6 - RIGHT FRONT STRUT TOWER - CONNECTOR - A/C PRESSURE TRANSDUCER - RIGHT WIPER MODULE DRAIN TUBE - HIGH SIDE SERVICE PORT - LIQUID LINE (3) Using an open end wrench, unscrew the A/C pressure transducer from the fitting on the liquid line between the filter-drier and the expansion valve. (4) Remove the seal from the A/C pressure transducer fitting and discard. INSTALLATION (1) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the A/C pressure transducer fitting. (2) Using an open end wrench, install and tighten the A/C pressure transducer onto the fitting on the liquid line between the filter-drier and the expansion valve. (3) Reconnect the headlamp and dash wire harness connector for the A/C pressure transducer to the transducer connector receptacle. (4) Reconnect the battery negative cable. BLEND DOOR ACTUATOR DESCRIPTION The blend door actuators are reversible, 12-volt Direct Current (DC), servo motors. Models with the single zone heater and air conditioner system have a single blend air door, which is controlled by a single blend door actuator. Models with the optional dual zone front heater and air conditioner system have dual blend air doors, which are controlled by two blend door actuators. The single zone blend door actuator is located on the driver side end of the heater-A/C housing unit, close to the dash panel. In the dual zone system, the same blend door actuator used for the single zone system becomes the passenger blend door actuator, and is mechanically connected to only the passenger side blend air door. In the dual zone system, a second separate blend door actuator is also located on the driver side end of the heater-A/C housing unit close to the instrument panel, and is mechanically connected to only the driver side blend air door. The blend door actuators are interchangeable with each other, as well as with the actuators for the mode door and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the heaterA/C unit housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the proper blend air door. The blend door actuators do not require mechanical indexing to the blend door linkage, as they are electronically calibrated by the heater-A/C control module. The blend door actuators cannot be adjusted or repaired and, if damaged or faulty, they must be replaced. OPERATION Each blend door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness. The blend door actuator can move the blend air door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the blend air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the blend air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the blend air door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative positions of the blend door actuator and the blend air door. The heater-A/C control module learns the blend air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuator can be diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. 24 - 12 CONTROLS - FRONT RS BLEND DOOR ACTUATOR (Continued) REMOVAL The single zone heating and air conditioning system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend air door and one for the passenger side blend air door. The same service procedures can be used for each of these actuators. 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 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. (1) Disconnect and isolate the battery negative cable. (2) Remove the silencer from beneath the driver side end of the instrument panel. (Refer to 23 BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SILENCER - REMOVAL). (3) Remove the three screws that secure the heater core shield to the left end of the HVAC distribution housing (Fig. 4). (4) Pull the heater core shield rearward far enough to disengage the two location tabs that position the front of the shield to the receptacles in the two lower finger formations of the heater/ air conditioner housing near the dash panel. (5) Remove the heater core shield from the distribution housing. (6) Disconnect the HVAC wire harness connector for the blend door actuator from the actuator connector receptacle (Fig. 5). Fig. 5 Blend Door Actuator 1 - CONNECTOR 2 - MODE DOOR ACTUATOR 3 - SCREW (2) 4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE ONLY) 5 - HEATER CORE 6 - BLEND DOOR ACTUATOR (SINGLE ZONE) OR PASSENGER BLEND DOOR ACTUATOR (DUAL-ZONE) (7) Remove the two screws that secure the blend door actuator to the distribution housing. (8) Remove the blend door actuator from the distribution housing. INSTALLATION Fig. 4 Heater Core Shield 1 2 3 4 5 - HEATER/ AIR CONDITIONER HOUSING HEATER CORE SHIELD DISTRIBUTION HOUSING SCREWS (3) LOCATION TABS (2) (1) Position the blend door actuator onto the heater/air conditioner housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door linkage. (2) Install and tighten the two screws that secure the blend door actuator to the distribution housing. Tighten the screws to 2 N·m (17 in. lbs.). (3) Reconnect the HVAC wire harness connector for the blend door actuator to the actuator connector receptacle. (4) Position the heater core shield onto the distribution housing. Be certain that the two location tabs on the front of the shield are engaged in the receptacles in the two lower finger formations of the evaporator housing near the dash panel. CONTROLS - FRONT RS 24 - 13 BLEND DOOR ACTUATOR (Continued) (5) Install and tighten the three screws that secure the heater core shield to the left end of the heater/air conditioner housing. Tighten the screws to 2 N·m (17 in. lbs.). (6) Reinstall the silencer under the driver side end of the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SILENCER - INSTALLATION). (7) Reconnect the battery negative cable. (8) Perform the heater-A/C control calibration procedure. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION). BLOWER MOTOR RELAY DESCRIPTION Fig. 6 Blower Motor Relay NUMBER 30 85 86 87 87A IDENTIFICATION COMMON FEED COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED The blower motor relay (Fig. 6) is a International Standards Organization (ISO) mini-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO mini-relay terminal functions are the same as a conventional ISO relay. However, the ISO mini-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The blower motor relay is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for blower motor relay identification and location. The black, molded plastic case is the most visible component of the blower motor relay. Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. OPERATION The blower motor relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control the high current output to the blower motor resistor (manual heaterA/C control) or blower power module (ATC control). The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the Intelligent Power Module (IPM). The inputs and outputs of the blower motor relay include: • The common feed terminal (30) receives a battery current input from the battery through a B(+) circuit at all times. • The coil ground terminal (85) receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground. • The coil battery terminal (86) receives a battery current input from the battery through a B(+) circuit at all times. • The normally open terminal (87) provides a battery current output to the blower motor resistor (manual heater-A/C control) or blower power module (automatic heater-A/C control) through a fuse in the IPM on the fused front blower motor relay output circuit only when the blower motor relay coil is energized. • The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the blower motor relay coil is de-energized. 24 - 14 CONTROLS - FRONT RS BLOWER MOTOR RELAY (Continued) 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. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Unlatch and remove the cover from the Intelligent Power Module (IPM) (Fig. 8). DIAGNOSIS AND TESTING - BLOWER MOTOR RELAY The front blower motor relay (Fig. 7) is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for front blower motor relay identification and location. Remove the relay from the IPM to perform the following tests: Fig. 8 Intelligent Power Module 1 - BATTERY THERMAL GUARD 2 - INTELLIGENT POWER MODULE 3 - FRONT CONTROL MODULE Fig. 7 Blower Motor Relay - Terminal Legend NUMBER 30 85 86 87 87A IDENTIFICATION COMMON FEED COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. (2) Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. (3) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, use a DRBIIIt scan tool to perform further diagnosis of the relay circuits. Refer to the appropriate diagnostic information. If not OK, replace the faulty relay. (3) See the fuse and relay layout map molded into the inner surface of the IPM cover for front blower motor relay identification and location. (4) Remove the front blower motor relay from the IPM by pulling the relay straight up. INSTALLATION (1) See the fuse and relay layout map molded into the inner surface of the Intelligent Power Module (IPM) cover for front blower motor relay identification and location. (2) Position the front blower motor relay to the proper receptacle in the IPM. (3) Align the front blower motor relay terminals with the terminal cavities in the IPM relay receptacle. (4) Push down firmly on the front blower motor relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. (5) Install and latch the cover onto the IPM. (6) Reconnect the battery negative cable. CONTROLS - FRONT RS BLOWER MOTOR RESISTOR DESCRIPTION Fig. 9 Blower Motor Resistor 1 2 3 4 5 6 - BLOWER MOTOR RESISTOR INSTRUMENT PANEL WIRE HARNESS SCREW (2) GLOVE BOX OPENING LOWER REINFORCEMENT BLOWER MOTOR PIGTAIL WIRE EVAPORATOR HOUSING A blower motor resistor is used on this model when it is equipped with the manual heater-A/C control (Fig. 9). Models equipped with the optional Automatic Temperature Control (ATC) use a blower power module, instead of the blower motor resistor. The blower motor resistor is installed in a mounting hole in the heater/AC housing, directly behind the glove box opening of the instrument panel. The resistor consists of a molded plastic mounting plate with two integral connector receptacles. Concealed behind the mounting plate within the heater/AC housing are four coiled resistor wires contained within a protective stamped steel cage. The resistor mounting plate is secured with two screws to the heater/AC housing and is accessed for service by rolling down the glove box from the instrument panel. The blower motor resistor wires will get hot when in use. Do not touch the resistor wires or the protective cage if the blower motor has been running. The blower motor resistor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. 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. A second connector receptacle receives the pigtail wire connector from the blower motor. The blower motor resistor has multiple resistor wires, each of 24 - 15 which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor switch in the manual heater-A/C control directs the ground path for the blower motor through the correct resistor wire to obtain the selected speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through all of the resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistor wires are bypassed and the blower motor receives a direct path to ground through the blower motor switch. The blower motor resistor may be diagnosed using conventional diagnostic tools and methods. DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR 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. 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 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. (1) Disconnect and isolate the battery negative cable. (2) Disconnect the instrument panel wire harness connector for the blower motor resistor and the blower motor pigtail wire connector from the resistor connector receptacles. (3) Check for continuity between each of the blower motor switch input terminals of the blower motor resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the instrument panel wire harness circuits between the blower motor switch and the blower motor resistor or the blower motor pigtail wires as required. If not OK, replace the faulty blower motor resistor. 24 - 16 CONTROLS - FRONT RS BLOWER MOTOR RESISTOR (Continued) 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 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. Fig. 10 Blower Motor Resistor WARNING: THE BLOWER MOTOR RESISTOR MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON, WAIT FIVE MINUTES TO ALLOW THE BLOWER MOTOR RESISTOR TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN 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. (1) Disconnect and isolate the battery negative cable. (2) Open the glove box. (3) Flex both sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening, then roll the glove box downward. (4) Reach through the glove box opening to access and disconnect the instrument panel wire harness connector for the blower motor resistor from the resistor connector receptacle (Fig. 10). (5) Reach through the glove box opening to access and disconnect the blower motor pigtail wire connector from the resistor connector receptacle. (6) Remove the two screws that secure the blower motor resistor to the evaporator housing. (7) Remove the blower motor resistor from the evaporator housing. INSTALLATION 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. 1 2 3 4 5 6 - BLOWER MOTOR RESISTOR INSTRUMENT PANEL WIRE HARNESS SCREW (2) GLOVE BOX OPENING LOWER REINFORCEMENT BLOWER MOTOR PIGTAIL WIRE EVAPORATOR HOUSING (1) Position the blower motor resistor into the evaporator housing. (2) Install and tighten the two screws that secure the blower motor resistor to the evaporator housing. Tighten the screws to 2 N·m (17 in. lbs.). (3) Reconnect the blower motor pigtail wire connector to the blower motor resistor connector receptacle. (4) Reconnect the instrument panel wire harness connector for the blower motor resistor to the resistor connector receptacle. (5) Flex both sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening, then roll the glove box upward. (6) Close and latch the glove box. (7) Reconnect the battery negative cable. COMPRESSOR CLUTCH DESCRIPTION The compressor clutch assembly consists of a stationary electromagnetic coil with a zener diode, a hub bearing and pulley assembly, and a clutch plate (Fig. 11). The electromagnetic coil unit and the hub bearing and pulley assembly are each retained on the nose of the compressor front housing with snap rings. The clutch plate is keyed or splined to the compressor shaft, and secured with a bolt. CONTROLS - FRONT RS 24 - 17 COMPRESSOR CLUTCH (Continued) ule (PCM) in the engine compartment, and the compressor clutch relay in the Intelligent Power Module (IPM). The PCM may delay compressor clutch engagement for up to thirty seconds. (Refer to 8 ELECTRICAL/ELECTRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE DESCRIPTION - PCM OPERATION). STANDARD PROCEDURE STANDARD PROCEDURE - COMPRESSOR CLUTCH AIR GAP Fig. 11 Compressor Clutch - Typical 1 2 3 4 5 6 7 - CLUTCH PLATE SHAFT KEY (SOME MODELS) PULLEY AND BEARING CLUTCH COIL CLUTCH SHIMS SNAP RING SNAP RING If a new clutch plate and/or clutch pulley are being used, the air gap between the clutch plate and clutch pulley must be checked using the following procedure: (1) Using feeler gauges, measure the air gap between the clutch plate and the clutch pulley friction surfaces. (2) If the air gap is not between 0.5 and 0.9 mm (0.020 and 0.035 in.), add or subtract shims until the desired air gap is obtained. The compressor clutch plate and pulley unit, or the clutch coil are available for separate service replacement. The clutch coil zener diode is integral to the clutch coil pigtail wire and connector and, if faulty or damaged, the clutch electromagnetic coil unit must be replaced. NOTE: The shims may compress after tightening the compressor shaft bolt. Check the air gap in four or more places on the clutch plate to verify that the air gap is still correct. Spin the clutch pulley before making the final air gap check. OPERATION STANDARD PROCEDURE - COMPRESSOR CLUTCH BREAK-IN The compressor clutch components provide the means to engage and disengage the compressor from the engine serpentine accessory drive belt. When the clutch coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley. A zener diode is connected in parallel with the clutch electromagnetic coil. This diode controls the dissipation of voltage induced into the coil windings by the collapsing of the electromagnetic fields that occurs when the compressor clutch is disengaged. The zener diode dissipates this induced voltage by regulating a current path to ground. This arrangement serves to protect other circuits and components from potentially damaging voltage spikes in the vehicle electrical system that might occur if the voltage induced in the clutch coil windings could not be dissipated. The compressor clutch engagement is controlled by several components: the heater-A/C controls in the passenger compartment, the A/C pressure transducer on the liquid line, the evaporator temperature sensor on the expansion valve, the Powertrain Control Mod- After a new compressor clutch has been installed, check that the compressor clutch coil is performing to specifications. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/COMPRESSOR CLUTCH COIL - DIAGNOSIS AND TESTING). If the clutch coil is performing to specifications, perform the compressor clutch break-in procedure. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. (1) Set the heater-A/C controls to the A/C mode, with the blower switch in the highest speed position. (2) Start the engine and hold the engine speed at 1500 to 2000 rpm. (3) Cycle the compressor clutch On and Off about twenty times (five seconds On, then five seconds Off). REMOVAL The refrigerant system can remain fully charged during compressor clutch, pulley, or coil replacement. Although the compressor assembly must be removed from its mounting, the compressor clutch can be service with the compressor in the vehicle. 24 - 18 CONTROLS - FRONT RS COMPRESSOR CLUTCH (Continued) (1) Disconnect and isolate the battery negative cable. (2) Raise and support the vehicle. (3) Remove the serpentine drive belt. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS 2.4L - REMOVAL) or (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - 3.3/3.8L - REMOVAL). (4) Disconnect the engine wire harness connector for the compressor clutch coil from the clutch coil pigtail wire connector on the top of the compressor. (5) On models with the 3.3L and 3.8L engines, disengage the retainer on the engine wire harness compressor clutch coil take out from the bracket on the top of the compressor. (6) On models with the 2.4L engine, remove all of the compressor mounting screws except the upper left (rear of the compressor) screw, which should only be loosened. Allow the front (pulley end) of the compressor to tilt downward far enough to access the clutch for removal, then tighten the loosened upper left compressor mounting screw. (7) On models with the 3.3L and 3.8L engines, remove the three screws and one nut that secure the compressor to the engine. Disengage the mounting ear at the front of the compressor from the stud on the engine, allow the front (pulley end) of the compressor to tilt downward far enough to access the clutch for removal, then reinstall and tighten the upper left compressor mounting screw. (8) Remove the compressor shaft bolt (Fig. 12). If necessary, a band-type oil filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt removal. (9) Tap the clutch plate lightly with a plastic hammer and remove the clutch plate and shim(s) from the compressor shaft (Fig. 13). Be certain not to lose the shim or shims. CAUTION: Do not pry between the clutch plate unit and the pulley to remove the clutch plate from the compressor shaft as this may damage the clutch plate. (10) Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the pulley to the front cover of the compressor, then slide the pulley off of the compressor (Fig. 14). (11) Remove the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing. (12) Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the clutch coil to the front cover of the compressor housing, then slide the clutch coil off of the compressor (Fig. 15). Fig. 12 Compressor Shaft Bolt and Clutch Plate 1 - COMPRESSOR SHAFT BOLT 2 - COMPRESSOR CLUTCH PLATE Fig. 13 Clutch Plate and Shim(s) 1 - COMPRESSOR SHAFT 2 - CLUTCH PLATE 3 - CLUTCH PLATE SHIM INSPECTION - COMPRESSOR CLUTCH/COIL Compressor clutch components should always be inspected closely before they are reinstalled. The clutch plate and clutch pulley are mated at the factory using a burnishing operation. No attempt should be made to separately replace the compressor clutch pulley or clutch plate. The clutch coil may be serviced separately. CONTROLS - FRONT RS 24 - 19 COMPRESSOR CLUTCH (Continued) and clutch plate should be replaced if there is excessive wear or scoring. (2) Examine the friction surfaces of the clutch pulley and the clutch plate for oil contamination. If the friction surfaces are oily, the clutch pulley and clutch plate should be replaced. Also inspect the shaft and nose area of the compressor for oil. Remove the felt packing from around the compressor shaft in the compressor front cover. If the felt is saturated with oil, the compressor front shaft seal is leaking and the compressor will also have to be replaced. (3) Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the clutch pulley and clutch plate if the bearing is faulty. INSTALLATION Fig. 14 Remove Clutch Pulley Snap Ring 1 - SNAP RING The refrigerant system can remain fully charged during compressor clutch, pulley, or coil replacement. Although the compressor assembly must be removed from its mounting, the compressor clutch can be service with the compressor in the vehicle. (1) Align the dowel pin on the back of the clutch coil with the hole in the compressor front cover, and position the clutch coil onto the compressor. Be certain that the clutch coil pigtail wires are properly oriented and routed so that they are not pinched between the compressor front cover and the clutch coil. NOTE: A new snap ring must be used to secure the clutch coil to the compressor. The bevel side of the snap ring must face outward. (2) Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring that secures the clutch coil to the front cover of the compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or the left of the clutch coil dowel pin location on the compressor. Be certain that the snap ring is fully and properly seated in the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the compressor front cover. Fig. 15 Remove Clutch Coil Snap Ring 1 2 3 4 - SNAP RING PLIERS CLUTCH COIL COMPRESSOR SNAP RING (1) Examine the friction surfaces of the clutch pulley and the clutch plate for wear. The clutch pulley (3) Install and tighten the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing. (4) Install the pulley onto the front cover of the compressor. If necessary, tap the pulley gently with a block of wood placed on the pulley friction surface (Fig. 16). CAUTION: Do not mar the friction surfaces of the pulley. 24 - 20 CONTROLS - FRONT RS COMPRESSOR CLUTCH (Continued) Fig. 16 Install Clutch Pulley 1 - PULLEY ASSEMBLY 2 - WOOD BLOCK NOTE: A new snap ring must be used to secure the clutch pulley to the compressor. The bevel side of the snap ring must face outward. (5) Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring (bevel side facing outward) that secures the clutch pulley to the front cover of the compressor. Be certain that the snap ring is fully and properly seated in the groove. (6) If the original clutch plate and clutch pulley are to be reused, reinstall the original shim(s) on the compressor shaft against the shoulder. If a new clutch plate and/or clutch pulley are being used, install a trial stack of shims 1.0 mm (0.040 in.) thick on the compressor shaft against the shoulder. (7) Install the clutch plate onto the compressor shaft. (8) Install and tighten the compressor shaft nut. If necessary, a band-type oil filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt tightening. Tighten the bolt to 17.5 N·m (155 in. lbs.). (9) If a new clutch plate and/or clutch pulley are being installed, the air gap between the clutch plate and clutch pulley must be checked. (Refer to 24 HEATING & AIR CONDITIONING/CONTROLS FRONT/COMPRESSOR CLUTCH - STANDARD PROCEDURE - COMPRESSOR CLUTCH AIR GAP). (10) On models with the 2.4L engine only, loosely install the four screws that secure the compressor to the mounting bracket on the engine. Tighten the screws to 28 N·m (21 ft. lbs.). (11) On models with the 3.3L and 3.8L engines only, loosely install the three screws and one nut that secure the compressor to the engine. Tighten each of the fasteners using the following sequence to 54 N·m (40 ft. lbs.). • The upper screw at the rear of the compressor. • The lower screw at the rear of the compressor. • The lower screw at the front of the compressor. • The upper nut at the front of the compressor. (12) On models with the 3.3L and 3.8L engines only, engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the compressor. (13) Reconnect the engine wire harness connector for the compressor clutch coil to the coil pigtail wire connector on the top of the compressor. (14) Reinstall the serpentine accessory drive belt onto the front of the engine. (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - 2.4L INSTALLATION) or (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - 3.3L/3.8L - INSTALLATION). (15) Lower the vehicle. (16) Reconnect the battery negative cable. (17) If a new clutch plate and/or clutch pulley are being installed, the new clutch components must be burnished. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/COMPRESSOR CLUTCH - STANDARD PROCEDURE - COMPRESSOR CLUTCH BREAK-IN). COMPRESSOR CLUTCH COIL DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH COIL The air conditioning compressor clutch coil electrical circuit is controlled by the Powertrain Control Module (PCM) through the compressor clutch relay, which is located in the Intelligent Power Module (IPM) in the engine compartment near the battery. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks. PRELIMINARY CHECKS (1) If the compressor clutch will not engage, verify the refrigerant charge level. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT - DIAGNOSIS AND TESTING REFRIGERANT CHARGE LEVEL). If the refrigerant charge level is OK, go to Step 2. If the refrigerant charge level is not OK, adjust the refrigerant charge as required. CONTROLS - FRONT RS 24 - 21 COMPRESSOR CLUTCH COIL (Continued) (2) If the a/c compressor clutch still will not engage, disconnect the headlamp and dash wire harness connector for the A/C pressure transducer and check for battery current at the connector with the engine running and the heater-A/C control set to the A/C mode. If OK, go to TESTS . If not OK, use a DRBIIIt scan tool to perform further diagnosis. Refer to the appropriate diagnostic information. TESTS (1) Verify the battery state of charge. (Refer to 8 ELECTRICAL/BATTERY SYSTEM/BATTERY DIAGNOSIS AND TESTING). (2) Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil. (3) With the heater-A/C control in the A/C mode and the blower at low speed, start the engine and allow it to run at a normal idle speed. (4) The compressor clutch should engage immediately, and the clutch coil voltage should be within two volts of the battery voltage. If the coil voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop. If the compressor clutch does not engage, use a DRBIIIt scan tool to perform further diagnosis. Refer to the appropriate diagnostic information. (5) With the ambient temperature at 21° C (70° F), the compressor clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5 to 12.5 volts at the clutch coil. If the voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until the voltage reads below 12.5 volts. (a) If the compressor clutch coil current reading is zero, the coil is open and must be replaced. (b) If the compressor clutch coil current reading is four amperes or more, the coil is shorted and must be replaced. COMPRESSOR CLUTCH RELAY DESCRIPTION The compressor clutch relay (Fig. 17) is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is located in the Intelli- gent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the compressor clutch relay. Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. OPERATION The compressor clutch relay is an electromechanical switch that uses a low current input from the Powertrain Control Module (PCM) to control the high current output to the compressor clutch electromagnetic coil. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The compressor clutch relay terminals are connected to the vehicle electrical system through a receptacle in the Intelligent Power Module (IPM). The inputs and outputs of the compressor clutch relay include: • The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. • The coil ground terminal (85) receives a ground input from the PCM through the compressor clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. • The coil battery terminal (86) receives a battery current input from the PCM through a fused ignition switch output (run-start) circuit only when the ignition switch is in the On or Start positions. • The normally open terminal (87) provides a battery current output to the compressor clutch coil through the compressor clutch relay output circuit only when the compressor clutch relay coil is energized. • The normally closed terminal (87A) is not connected to any circuit in this application, but provides 24 - 22 CONTROLS - FRONT RS COMPRESSOR CLUTCH RELAY (Continued) a battery current output only when the compressor clutch relay coil is de-energized. 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. DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH RELAY The compressor clutch relay (Fig. 17) is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location. Remove the relay from the IPM to perform the following tests: (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. (2) Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. (3) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, use a DRBIIIt scan tool to perform further diagnosis of the relay circuits. Refer to the appropriate diagnostic information. If not OK, replace the faulty relay. TERMINAL LEGEND NUMBER IDENTIFICATION 30 COMMON FEED 85 COIL GROUND 86 COIL BATTERY 87 NORMALLY OPEN 87A NORMALLY CLOSED REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Unlatch and remove the cover from the Intelligent Power Module (IPM). (3) See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location. (4) Remove the compressor clutch relay from the IPM by pulling it straight up. INSTALLATION (1) See the fuse and relay layout map molded into the inner surface of the Intelligent Power Module (IPM) cover for compressor clutch relay identification and location. (2) Position the compressor clutch relay to the proper receptacle in the IPM. (3) Align the compressor clutch relay terminals with the terminal cavities in the IPM relay receptacle. (4) Push down firmly on the compressor clutch relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. (5) Install and latch the cover onto the IPM. (6) Reconnect the battery negative cable. EVAPORATOR TEMPERATURE SENSOR DESCRIPTION Fig. 17 Compressor Clutch Relay The evaporator temperature sensor is a switch that is installed on the top of the expansion valve in the right rear corner of the engine compartment (Fig. 18). The sensor has a small probe that is inserted in a small well in the body of the expansion valve that is filled with a special silicone-based thermal grease. A small molded plastic push-in retainer secures the sensor to a threaded hole in the top surface of the expansion valve. Two terminals within a molded plastic connector receptacle on the sensor connect it to the vehicle electrical system through a take out and connector of the HVAC wire harness. CONTROLS - FRONT RS 24 - 23 EVAPORATOR TEMPERATURE SENSOR (Continued) REMOVAL Fig. 18 Evaporator Temperature Sensor 1 2 3 4 5 - RIGHT FRONT STRUT TOWER EVAPORATOR TEMPERATURE SENSOR EXPANSION VALVE DASH PANEL RETAINER (1) Disconnect and isolate the battery negative cable. (2) Remove the air cleaner housing from the right side of the engine compartment. (3) Remove the windshield wiper assembly from the vehicle(Refer to 8 - ELECTRICAL/WIPERS/ WASHERS/WIPER MODULE - REMOVAL). (4) Remove the temperature sensor attaching screw from the expansion valve. (5) Pull the evaporator temperature sensor away from the expansion valve far enough to access the red release ring on the wiring connector. Push the red ring toward the connector to release lock and remove the HVAC wire harness connector from the temperature sensor. (6) Remove the evaporator temperature sensor from the engine compartment. Please note that any grease removed with the old temperature sensor must be replaced, failure to do so could result in poor a/c performance. INSTALLATION The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION The evaporator temperature sensor monitors the temperature of the evaporator through its connection to the top of the expansion valve. The sensor will change its internal resistance in response to the temperatures it monitors. The heater-A/C control module is connected to the sensor through a sensor ground circuit and a sensor signal circuit. As the evaporator temperature increases, the resistance of the sensor decreases and the voltage monitored by the module decreases. The module uses this monitored voltage reading to an indication of the evaporator temperature. The heater-A/C control module is programmed to respond to this input by sending electronic messages to the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus, and the PCM then cycles the air conditioning compressor clutch as necessary to optimize air conditioning system performance and to protect the system from evaporator freezing. The external location of the sensor and the use of a screw allows the sensor to be removed or installed from the expansion valve without disturbing the refrigerant in the system. The evaporator temperature sensor is diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. (1) Position the evaporator temperature sensor into the right rear corner of the engine compartment. Please make sure any grease removed with the old sensor has been replaced before the new sensor is installed, failure to do so could lead to poor a/c performance. (2) Reconnect the HVAC wire harness connector for the evaporator temperature sensor to the sensor connector receptacle. (3) Position the evaporator temperature sensor onto the top of the expansion valve with the sensor probe inserted into the well in the expansion valve. (4) Install the temperature sensor retaining screw and tighten. (5) Install the window wiper assembly to the vehicle(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER MODULE - INSTALLATION). (6) Reinstall the air cleaner housing into the right side of the engine compartment. (7) Reconnect the battery negative cable. (8) Run the HVAC Cool Down test to verify system is operating properly(Refer to 24 - HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING). 24 - 24 CONTROLS - FRONT INFRARED TEMPERATURE SENSOR DESCRIPTION RS evaporative heat loss. The ATC system logic responds to the infrared sensor inputs by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the individually selected comfort level temperatures of both the driver and passenger seat occupants. The ATC heater-A/C control module continually monitors the infrared sensor circuits, and will store a Diagnostic Trouble Code (DTC) for any problem it detects. This DTC information can be retrieved and the infrared temperature sensor diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. MODE DOOR ACTUATOR DESCRIPTION Fig. 19 Infrared Temperature Sensor 1 - INSTRUMENT PANEL CENTER BEZEL 2 - CENTER BEZEL OUTLETS 3 - INFRARED TEMPERATURE SENSOR The infrared temperature sensor consists of two infrared transducers that are concealed behind a clear lens located near the bottom of the center panel outlet near the top of the instrument panel center bezel (Fig. 19). These sensors are used only on models equipped with the optional Automatic Temperature Control (ATC) heating and air conditioning system. A molded plastic connector receptacle on the bottom of the panel outlet unit is concealed behind the center bezel. A short, dedicated jumper wire harness routed behind the center bezel connects the sensors directly to the ATC heater-A/C control module near the bottom of the center bezel. The infrared temperature sensor is integral to the center bezel panel outlet unit. The infrared sensors cannot be adjusted or repaired and, if faulty or damaged, the center bezel panel outlet unit must be replaced. OPERATION The dual infrared temperature sensors provide independent measurement inputs to the Automatic Temperature Control (ATC) heater-A/C control module that indicates the surface temperature of the driver seat and front seat passenger seat occupants. By using a surface temperature measurement, rather than an air temperature measurement, the ATC system is able to adjust itself to the comfort level as perceived by the occupant. This allows the system to detect and compensate for other ambient conditions affecting comfort levels, such as solar heat gain or Fig. 20 Mode Door Actuator 1 - CONNECTOR 2 - MODE DOOR ACTUATOR 3 - SCREW (2) 4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE ONLY) 5 - HEATER CORE 6 - BLEND DOOR ACTUATOR (SINGLE ZONE) OR PASSENGER BLEND DOOR ACTUATOR (DUAL-ZONE) The mode door actuator is a reversible, 12-volt Direct Current (DC), servo motor (Fig. 20). The single mode door actuator is located on the driver side end of the heater-A/C housing unit, close to the top of the distribution housing. The mode door actuator is mechanically connected to the mode door. The mode door actuator is interchangeable with the actuators for the blend air door(s) and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the heater-A/C unit housing. Each actuator also has an identical output shaft with splines that connects CONTROLS - FRONT RS 24 - 25 MODE DOOR ACTUATOR (Continued) it to the linkage that drives the mode door. The mode door actuator does not require mechanical indexing to the mode door linkage, as it is electronically calibrated by the heater-A/C control module. The mode door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. (3) Disconnect the HVAC wire harness connector for the mode door actuator from the actuator connector receptacle (Fig. 21). OPERATION The mode door actuator is connected to the heaterA/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness. The mode door actuator can move the mode door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the mode door will move in one direction. When the module reverses the polarity of the voltage to the motor, the mode door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the mode door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative position of the mode door actuator and the mode door. The heater-A/C control module learns the mode door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuator can be diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. (4) Remove the two screws that secure the mode door actuator to the distribution housing. (5) Remove the mode door actuator from the distribution housing. REMOVAL INSTALLATION 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 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. 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 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. (1) Disconnect and isolate the battery negative cable. (2) Remove the silencer from beneath the driver side end of the instrument panel. (Refer to 23 BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SILENCER - REMOVAL). (1) Position the mode door actuator onto the heater/AC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage. Fig. 21 Mode Door Actuator 1 - CONNECTOR 2 - MODE DOOR ACTUATOR 3 - SCREW (2) 4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE ONLY) 5 - HEATER CORE 6 - BLEND DOOR ACTUATOR (SINGLE ZONE) OR PASSENGER BLEND DOOR ACTUATOR (DUAL-ZONE) 24 - 26 CONTROLS - FRONT RS MODE DOOR ACTUATOR (Continued) (2) Install and tighten the two screws that secure the mode door actuator to the distribution housing. Tighten the screws to 2 N·m (17 in. lbs.). (3) Reconnect the HVAC wire harness connector for the mode door actuator to the actuator connector receptacle. (4) Reinstall the silencer under the driver side end of the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SILENCER - INSTALLATION). (5) Reconnect the battery negative cable. (6) Perform the heater-A/C control calibration procedure. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION). POWER MODULE DESCRIPTION and is accessed for service by rolling down the glove box from the instrument panel. The power module heat sink will get hot when in use. Do not touch the heat sink if the blower motor has been running. The blower power module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION The blower power module is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A second connector receptacle receives the pigtail wire connector from the blower motor. The blower power module allows the microprocessor-based Automatic Temperature Control (ATC) heater-A/C control module to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a Pulse Width Modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which adjusts the voltage output received from the blower motor relay to change or maintain the desired blower speed. The blower power module is diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. REMOVAL Fig. 22 Power Module 1 - POWER MODULE 2 - LOWER GLOVE BOX OPENING REINFORCEMENT 3 - EVAPORATOR HOUSING A blower power module is used on this model when it is equipped with the optional Automatic Temperature Control (ATC) (Fig. 22). Models equipped with the standard manual heater-A/C control use a blower motor resistor, instead of the blower power module. The blower power module is installed in a mounting hole in the evaporator housing, directly behind the glove box opening of the instrument panel. The module consists of a molded plastic mounting plate with two integral connector receptacles. Concealed behind the mounting plate within the evaporator housing is the power module electronic circuitry and a large finned, heat sink. The module mounting plate is secured with two screws to the evaporator housing 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 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. (1) Disconnect and isolate the battery negative cable. (2) Open the glove box. (3) Flex both sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening, then roll the glove box downward. (4) Reach through the glove box opening to access and disconnect the instrument panel wire harness CONTROLS - FRONT RS 24 - 27 POWER MODULE (Continued) connector for the power module from the module connector receptacle. (5) Reach through the glove box opening to access and disconnect the blower motor pigtail wire connector from the power module connector receptacle. (6) Remove the two screws that secure the power module to the evaporator housing. (7) Remove the power module from the evaporator housing. INSTALLATION 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 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. (1) Position the power module into the evaporator housing. (2) Install and tighten the two screws that secure the power module to the evaporator housing. Tighten the screws to 2 N·m (18 in. lbs.). (3) Reconnect the blower motor pigtail wire connector to the power module connector receptacle. (4) Reconnect the instrument panel wire harness connector for the power module to the module connector receptacle. (5) Flex both sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening, then roll the glove box upward. (6) Close and latch the glove box. (7) Reconnect the battery negative cable. RECIRCULATION DOOR ACTUATOR DESCRIPTION The recirculation door actuator is a reversible, 12-volt Direct Current (DC), servo motor (Fig. 23). The single recirculation door actuator is located on the passenger side end of the heater-A/C housing unit, on the bottom of the lower intake air housing. The recirculation door actuator is mechanically connected to the recirculation air door. The recirculation Fig. 23 Recirculation Door Actuator 1 2 3 4 5 - LOWER INTAKE AIR HOUSING RECIRCULATION DOOR ACTUATOR HVAC WIRE HARNESS SCREW (2) LOWER EVAPORATOR HOUSING door actuator is interchangeable with the actuators for the blend air door(s) and the mode door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the lower intake air housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the recirculation air door. The recirculation door actuator does not require mechanical indexing to the recirculation air door, as it is electronically calibrated by the heater-A/C control module. The recirculation door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. OPERATION The recirculation door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation door in two directions. When the heater-A/C control module 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 module reverses the polarity of the voltage to the motor, the recirculation air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the recirculation air door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal 24 - 28 CONTROLS - FRONT RS RECIRCULATION DOOR ACTUATOR (Continued) allows the module to monitor the operation and relative position of the recirculation door actuator and the recirculation air door. The heater-A/C control module 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 can be diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. 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 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. (1) Disconnect and isolate the battery negative cable. (2) Pull the carpet on the passenger side front floor away from the dash panel far enough to access the recirculation door actuator. (3) Disconnect the HVAC wire harness connector for the recirculation door actuator from the actuator connector receptacle (Fig. 24). (4) Remove the two screws that secure the recirculation door actuator to the lower intake air housing. (5) Remove the recirculation door actuator from the lower intake air housing. INSTALLATION 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 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. Fig. 24 Recirculation Door Actuator 1 2 3 4 5 - LOWER INTAKE AIR HOUSING RECIRCULATION DOOR ACTUATOR HVAC WIRE HARNESS SCREW (2) LOWER EVAPORATOR HOUSING (1) Position the recirculation door actuator onto the lower intake air housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation air door. (2) Install and tighten the two screws that secure the recirculation door actuator to the lower intake air housing. Tighten the screws to 2 N·m (17 in. lbs.). (3) Reconnect the HVAC wire harness connector for the recirculation door actuator to the actuator connector receptacle. (4) Reposition the carpet on the passenger side front floor back up to the dash panel. (5) Reconnect the battery negative cable. (6) Perform the heater-A/C control calibration procedure. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION). CONTROLS - REAR RS 24 - 29 CONTROLS - REAR TABLE OF CONTENTS page A/C-HEATER CONTROL REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BLEND DOOR ACTUATOR DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BLOWER MOTOR RELAY DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - BLOWER MOTOR RELAY . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . BLOWER MOTOR RESISTOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 . 30 . 31 . 31 . . . . . . . . 32 . . . . . . . . 32 . . . . . . . . 33 . . . . . . . . 33 . . . . . . . . 34 page OPERATION . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . INFRARED TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . MODE DOOR ACTUATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . POWER MODULE DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . 35 . . . . . . . . 35 . . . . . . . . 35 . . . . . . . . 36 . . . . . . . . 36 . . . . . . . . 36 . . . . . . . . 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . 37 . 38 . 38 . . . . . . . . 34 A/C-HEATER CONTROL REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Using a trim stick or another suitable wide flat bladed tool, gently pry the top edge of the rear heater-A/C control bezel away from the headliner far enough to release the two snap clip retainers (Fig. 1). (3) Pull the rear heater-A/C control and bezel unit rearward far enough to access the headliner wire harness connector on the back of the control. (4) Disconnect the headliner wire harness connector for the rear heater-A/C control from the control connector receptacle. (5) Remove the rear heater-A/C control from the headliner. (6) Remove the three screws that secure the rear heater-A/C control to the bezel (Fig. 2). (7) Remove the rear heater-A/C control from the bezel. INSTALLATION (1) Position the rear heater-A/C control onto the bezel. (2) Install and tighten the three screws that secure the rear heater-A/C control to the bezel. Tighten the screws to 2 N·m (17 in. lbs.). (3) Position the rear heater-A/C control and bezel unit to the headliner. Fig. 1 Heater-A/C Control 1 2 3 4 - TRIM STICK BEZEL HEATER-A/C CONTROL HEADLINER (4) Reconnect the headliner wire harness connector for the rear heater-A/C control to the control connector receptacle. (5) Insert the locator tabs on the back of the rear heater-A/C control and bezel unit over the forward edge of the headliner opening for the control. (6) Slide the rear heater-A/C control and bezel unit forward far enough to align the snap clips on the 24 - 30 CONTROLS - REAR RS A/C-HEATER CONTROL (Continued) Fig. 2 Heater-A/C Control Bezel 1 2 3 4 5 - BEZEL SNAP CLIP (2) HEATER-A/C CONTROL SCREW (3) LOCATOR TAB (2) bezel with the snap clip receptacles on the retainer above the headliner. (7) Using hand pressure, press the top edge of the rear heater-A/C control bezel upward until the two snap clips are fully seated in their receptacles. (8) Reconnect the battery negative cable. (9) Using the DRB-IIIt reset the Rear Temperature Selector calibration values. (10) Verify that the Actuator Calibration of the Front Control has passed. If an Actuator Calibration has not passed correct any errors before proceeding further. (11) Rotate the Rear Temperature Selector counter clockwise to the Cold Position, allow the Selector to remain in the Cold Position for 5 seconds. (12) Rotate the Rear Temperature Selector Clockwise to the Hot Position, allow the Selector to remain in the Cold Position for 5 seconds. (13) calibration is now complete. BLEND DOOR ACTUATOR DESCRIPTION The blend door actuator is a reversible, 12-volt Direct Current (DC), servo motor (Fig. 3). The single blend door actuator is located on the outboard side of the rear heater-A/C unit housing, below the mode door actuator. The blend door actuator is mechanically connected to the blend air door. The blend door actuator is interchangeable with the actuator for the mode door. Each actuator is contained within an identical black molded plastic housing with an inte- Fig. 3 Blend Door Actuator 1 2 3 4 5 6 - SCREW (2) MODE DOOR ACTUATOR SCREW (2) CONNECTOR BLEND DOOR ACTUATOR CONNECTOR gral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the rear heater-A/C unit housing. Each actuator also has an identical output shaft with splines that connects it to the pivot or linkage of the proper door. The blend door actuator does not require mechanical indexing to the blend air door pivot, as it is electronically calibrated by the front heater-A/C control module. The blend door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. OPERATION The blend door actuator is connected to the front heater-A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the rear HVAC wire harness. The blend door actuator can move the blend air door in two directions. When the front heater-A/C control module pulls the voltage on one side of the motor connection CONTROLS - REAR RS 24 - 31 BLEND DOOR ACTUATOR (Continued) high and the other connection low, the blend air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the blend air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the blend air door stops and will not move. These same motor connections also provide a feedback signal to the front heater-A/C control module. This feedback signal allows the module to monitor the operation and relative positions of the blend door actuator and the blend air door. The front heater-A/C control module learns the blend air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the blend door actuator circuits. A DTC can be retrieved and the blend door actuator can be diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL). (3) Remove the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. (4) Remove the screw that secures the back of the rear heater-A/C unit housing to the right D-pillar. (5) Remove the screw that secures the front of the rear heater-A/C unit housing to the right quarter inner panel. (6) Carefully pull the top of the rear heater-A/C unit housing away from the right quarter inner panel far enough to reach between the rear heater-A/C unit housing and the quarter inner panel to access the blend door actuator (Fig. 4). (7) Remove the two screws that secure the blend door actuator to the rear heater-A/C unit housing. (8) Pull the blend door actuator away from the rear heater-A/C unit housing far enough to disengage the actuator output shaft from the blend air door pivot. (9) Raise the blend door actuator far enough to access and disconnect the rear HVAC wire harness connector for the actuator from the actuator connector receptacle. (10) Remove the blend door actuator from between the rear heater-A/C unit housing and the quarter inner panel. Fig. 4 Mode Door Actuator 1 2 3 4 5 6 - SCREW (2) MODE DOOR ACTUATOR SCREW (2) CONNECTOR BLEND DOOR ACTUATOR CONNECTOR INSTALLATION (1) Position the blend door actuator between the rear heater-A/C unit housing and the quarter inner panel. (2) Reconnect the rear HVAC wire harness connector for the blend door actuator to the actuator connector receptacle. (3) Position the blend door actuator onto the rear heater-A/C unit housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door pivot. (4) Install and tighten the two screws that secure the blend door actuator to the rear heater-A/C unit housing. Tighten the screws to 2 N·m (18 in. lbs.). (5) Push the top of the rear heater-A/C unit housing back into position against the right quarter inner panel. (6) Install and tighten the screw that secures the front of the rear heater-A/C unit housing to the right 24 - 32 CONTROLS - REAR RS BLEND DOOR ACTUATOR (Continued) quarter inner panel. Tighten the screw to 11 N·m (97 in. lbs.). (7) Install and tighten the screw that secures the back of the rear heater-A/C unit housing to the right D-pillar. Tighten the screw to 11 N·m (97 in. lbs.). (8) Install and tighten the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Tighten the screws to 1.7 N·m (15 in. lbs.). (9) Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION). (10) Reconnect the battery negative cable. (11) Perform the heater-A/C control calibration procedure. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION). BLOWER MOTOR RELAY DESCRIPTION patterns, and terminal functions. The ISO mini-relay terminal functions are the same as a conventional ISO relay. However, the ISO mini-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The blower motor relay is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the blower motor relay. Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. The ISO terminal designations are as follows: • 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. • 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. • 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. • 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. • 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The factory-installed blower motor relay cannot be adjusted or repaired. If the relay is damaged or faulty, it must be replaced. OPERATION Fig. 5 Blower Motor Relay TERMINAL LEGEND NUMBER IDENTIFICATION 30 COMMON FEED 85 COIL GROUND 86 COIL BATTERY 87 NORMALLY OPEN 87A NORMALLY CLOSED The blower motor relay (Fig. 5) is a International Standards Organization (ISO) mini-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal The blower motor relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control the high current output to the blower motor resistor (manual heaterA/C control) or blower power module (automatic heater-A/C control). The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. CONTROLS - REAR RS 24 - 33 BLOWER MOTOR RELAY (Continued) The blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the Intelligent Power Module (IPM). The inputs and outputs of the compressor clutch relay include: • The common feed terminal (30) receives a battery current input from the battery through a B(+) circuit at all times. • The coil ground terminal (85) receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground. • The coil battery terminal (86) receives a battery current input from the battery through a B(+) circuit at all times. • The normally open terminal (87) provides a battery current output to the blower motor resistor (manual heater-A/C control) or blower power module (automatic heater-A/C control) through a fuse in the IPM on the fused rear blower motor relay output circuit only when the blower motor relay coil is energized. • The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the blower motor relay coil is de-energized. 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. Fig. 6 Blower Motor Relay NUMBER 30 85 86 87 87A IDENTIFICATION COMMON FEED COIL GROUND COIL GROUND NORMALLY OPEN NORMALLY CLOSED REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Unlatch and remove the cover from the Intelligent Power Module (IPM) (Fig. 7). DIAGNOSIS AND TESTING - BLOWER MOTOR RELAY The rear blower motor relay (Fig. 6) is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for rear blower motor relay identification and location. Remove the relay from the IPM to perform the following tests: (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. (2) Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. (3) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, use a DRBIIIt scan tool to perform further diagnosis of the relay circuits. Refer to the appropriate diagnostic information. If not OK, replace the faulty relay. Fig. 7 Intelligent Power Module 1 - BATTERY THERMAL GUARD 2 - INTELLIGENT POWER MODULE 3 - FRONT CONTROL MODULE 24 - 34 CONTROLS - REAR RS BLOWER MOTOR RELAY (Continued) (3) See the fuse and relay layout map molded into the inner surface of the IPM cover for rear blower motor relay identification and location. (4) Remove the rear blower motor relay from the IPM. INSTALLATION (1) See the fuse and relay layout map molded into the inner surface of the Intelligent Power Module (IPM) cover for rear blower motor relay identification and location. (2) Position the rear blower motor relay to the proper receptacle in the IPM. (3) Align the rear blower motor relay terminals with the terminal cavities in the IPM relay receptacle. (4) Push down firmly on the rear blower motor relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. (5) Install and latch the cover onto the IPM. (6) Reconnect the battery negative cable. BLOWER MOTOR RESISTOR DESCRIPTION A blower motor resistor is used on this model when it is equipped with the manual heater-A/C control (Fig. 8). Models equipped with the optional Automatic Temperature Control (ATC) use a blower power module, instead of the blower motor resistor. The blower motor resistor is installed in a mounting hole on the back of the rear heater-A/C unit housing, directly above the expansion valve. The resistor consists of a molded plastic mounting plate with an integral connector receptacle. Concealed behind the mounting plate within the rear heater-A/C unit housing are two coiled resistor wires contained within a protective stamped steel cage. The resistor mounting plate is secured with two screws to the rear heaterA/C unit housing and is accessed for service by removing the right quarter and D-pillar trim panels. The blower motor resistor wires will get hot when in use. Do not touch the resistor wires or the protective cage if the blower motor has been running. The blower motor resistor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION The blower motor resistor is connected to the vehicle electrical system through a dedicated take out and connector of the rear HVAC wire harness. The blower motor resistor has two resistor wires, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor switch in the manual heater-A/C con- Fig. 8 Blower Motor Resistor 1 2 3 4 5 6 7 - REAR HEATER-A/C UNIT HOUSING D-PILLAR BLOWER PIGTAIL WIRE CONNECTOR EXPANSION VALVE SCREW (2) BLOWER MOTOR RESISTOR trol directs the ground path for the blower motor through the correct resistor wire to obtain the selected speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through both resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistor wires are bypassed and the blower motor receives a direct path to ground through the blower motor switch. The blower motor resistor may be diagnosed using conventional diagnostic tools and methods. CONTROLS - REAR RS 24 - 35 BLOWER MOTOR RESISTOR (Continued) DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR 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. (1) Disconnect and isolate the battery negative cable. (2) Disconnect the rear HVAC wire harness connector for the blower motor resistor from the resistor connector receptacle. (3) Check for continuity between each of the blower motor switch input terminals of the blower motor resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or the blower motor pigtail wires as required. If not OK, replace the faulty blower motor resistor. REMOVAL WARNING: THE BLOWER MOTOR RESISTOR MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON, WAIT FIVE MINUTES TO ALLOW THE BLOWER MOTOR RESISTOR TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN 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. (1) Disconnect and isolate the battery negative cable. (2) Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL). (3) Disconnect the rear HVAC wire harness connector for the blower motor resistor from the resistor connector receptacle (Fig. 9). (4) Remove the two screws that secure the blower motor resistor to the rear heater-A/C unit housing. (5) Remove the blower motor resistor from the rear heater-A/C unit housing. Fig. 9 Blower Motor Resistor 1 2 3 4 5 6 7 - REAR HEATER-A/C UNIT HOUSING D-PILLAR BLOWER PIGTAIL WIRE CONNECTOR EXPANSION VALVE SCREW (2) BLOWER MOTOR RESISTOR INSTALLATION 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. (1) Position the blower motor resistor into the rear heater-A/C unit housing. (2) Install and tighten the two screws that secure the blower motor resistor to the rear heater-A/C unit housing. Tighten the screws to 2 N·m (17 in. lbs.). (3) Reconnect the rear HVAC wire harness connector for the blower motor resistor to the resistor connector receptacle. (4) Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION). (5) Reconnect the battery negative cable. 24 - 36 CONTROLS - REAR INFRARED TEMPERATURE SENSOR DESCRIPTION The rear infrared temperature sensor consists of an infrared transducer that is concealed behind the lens of the rear heater-A/C control in the headliner. This sensor is used only on models equipped with the optional Automatic Temperature Control (ATC) heating and air conditioning system. The rear infrared temperature sensor is integral to the rear heater-A/C control. The infrared sensor cannot be adjusted or repaired and, if faulty or damaged, the rear heaterA/C control unit must be replaced. RS (5) Remove the screw that secures the front of the rear heater-A/C unit housing to the right quarter inner panel. (6) Carefully pull the top of the rear heater-A/C unit housing away from the right quarter inner panel far enough to reach between the rear heater-A/C unit housing and the quarter inner panel to access the mode door actuator (Fig. 10). OPERATION The rear infrared temperature sensor provides an independent measurement input to the Automatic Temperature Control (ATC) heater-A/C control module that indicates the surface temperature of the rear seat occupants. By using a surface temperature measurement, rather than an air temperature measurement, the ATC system is able to adjust itself to the comfort level as perceived by the occupant. This allows the system to detect and compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor input by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperatures for the rear seat occupants. The ATC heater-A/C control module continually monitors the infrared sensor circuit, and will store a Diagnostic Trouble Code (DTC) for any problem it detects. This DTC information can be retrieved and the infrared temperature sensor diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. MODE DOOR ACTUATOR REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL). (3) Remove the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. (4) Remove the screw that secures the back of the rear heater-A/C unit housing to the right D-pillar. Fig. 10 Blend Door Actuator 1 2 3 4 5 6 - SCREW (2) MODE DOOR ACTUATOR SCREW (2) CONNECTOR BLEND DOOR ACTUATOR CONNECTOR (7) Remove the two screws that secure the mode door actuator to the rear heater-A/C unit housing. (8) Pull the mode door actuator away from the rear heater-A/C unit housing far enough to disengage the actuator output shaft from the mode door linkage. (9) Raise the mode door actuator far enough to access and disconnect the rear HVAC wire harness connector for the actuator from the actuator connector receptacle. CONTROLS - REAR RS 24 - 37 MODE DOOR ACTUATOR (Continued) (10) Remove the mode door actuator from between the rear heater-A/C unit housing and the quarter inner panel. INSTALLATION (1) Position the mode door actuator between the rear heater-A/C unit housing and the quarter inner panel. (2) Reconnect the rear HVAC wire harness connector for the mode door actuator to the actuator connector receptacle. (3) Position the mode door actuator onto the rear heater-A/C unit housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage. (4) Install and tighten the two screws that secure the mode door actuator to the rear heater-A/C unit housing. Tighten the screws to 2 N·m (18 in. lbs.). (5) Push the top of the rear heater-A/C unit housing back into position against the right quarter inner panel. (6) Install and tighten the screw that secures the front of the rear heater-A/C unit housing to the right quarter inner panel. Tighten the screw to 11 N·m (97 in. lbs.). (7) Install and tighten the screw that secures the back of the rear heater-A/C unit housing to the right D-pillar. Tighten the screw to 11 N·m (97 in. lbs.). (8) Install and tighten the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Tighten the screws to 1.7 N·m (15 in. lbs.). (9) Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION). (10) Reconnect the battery negative cable. (11) Perform the heater-A/C control calibration procedure. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION). POWER MODULE DESCRIPTION A blower power module is used on this model when it is equipped with the optional Automatic Temperature Control (ATC) (Fig. 11). Models equipped with the standard manual heater-A/C control use a blower motor resistor, instead of the blower power module. The blower power module is installed in a mounting hole in the back of the rear heater-A/C unit housing, directly above the expansion valve. The module consists of a molded plastic mounting plate with two Fig. 11 Power Module 1 2 3 4 5 6 7 - REAR HEATER-A/C UNIT HOUSING SCREW (2) D-PILLAR BLOWER PIGTAIL WIRE REAR HVAC WIRE HARNESS EXPANSION VALVE BLOWER POWER MODULE integral connector receptacles. Concealed behind the mounting plate within the evaporator housing is the power module electronic circuitry and a large finned, heat sink. The module mounting plate is secured with two screws to the rear heater-A/C unit housing and is accessed for service by removing the right quarter and D-pillar trim panels. The power module heat sink will get hot when in use. Do not touch the heat sink if the blower motor has been running. The blower power module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION The blower power module is connected to the vehicle electrical system through a dedicated take out and connector of the rear HVAC wire harness. A second connector receptacle receives the pigtail wire connector from the blower motor. The blower power module allows the microprocessor-based Automatic Temperature Control (ATC) heater-A/C control module to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a Pulse Width Modulated (PWM) circuit strategy. The PWM 24 - 38 CONTROLS - REAR RS POWER MODULE (Continued) voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which adjusts the voltage output received from the blower motor relay to change or maintain the desired blower speed. The blower power module is diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL). (3) Disconnect the rear HVAC wire harness connector for the blower power module from the resistor connector receptacle (Fig. 12). (4) Disconnect the blower motor pigtail wire connector from the blower power module connector receptacle. (5) Remove the two screws that secure the blower power module to the rear heater-A/C unit housing. (6) Remove the blower power module from the rear heater-A/C unit housing. INSTALLATION (1) Position the blower power module into the rear heater-A/C unit housing. (2) Install and tighten the two screws that secure the blower power module to the rear heater-A/C unit housing. Tighten the screws to 2 N·m (17 in. lbs.). (3) Reconnect the blower motor pigtail wire to the blower power module connector receptacle. (4) Reconnect the rear HVAC wire harness connector for the blower power module to the module connector receptacle. Fig. 12 Power Module 1 2 3 4 5 6 7 - REAR HEATER-A/C UNIT HOUSING SCREW (2) D-PILLAR BLOWER PIGTAIL WIRE REAR HVAC WIRE HARNESS EXPANSION VALVE BLOWER POWER MODULE (5) Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION). (6) Reconnect the battery negative cable. DISTRIBUTION - FRONT RS 24 - 39 DISTRIBUTION - FRONT TABLE OF CONTENTS page AIR FILTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . AIR OUTLETS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - CENTER BEZEL OUTLETS .. REMOVAL - DEMISTER OUTLET . . . . . . . . REMOVAL - FRONT DOOR REAR OUTLET REMOVAL - INSTRUMENT PANEL OUTLET INSTALLATION INSTALLATION - CENTER BEZEL OUTLETS INSTALLATION - DEMISTER OUTLET . . . . INSTALLATION - FRONT DOOR REAR OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - INSTRUMENT PANEL OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . BLOWER MOTOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40 . . 40 . . 40 . . 40 . . 41 . . 41 . . 41 . 42 . 43 . . 43 . . 43 . . 43 . . 43 page OPERATION . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . DEFROSTER DUCT REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . DEMISTER DUCTS REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . FLOOR DISTRIBUTION DUCTS REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . HVAC HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . PANEL DUCTS REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43 . . . . . . . . 44 . . . . . . . . 44 . . . . . . . . 46 . . . . . . . . 47 . . . . . . . . 47 . . . . . . . . 47 . . . . . . . . 48 . . . . . . . . 48 . . . . . . . . 48 . . . . . . . . 49 . . . . . . . . 50 . . . . . . . . 50 . . . . . . . . 50 24 - 40 DISTRIBUTION - FRONT RS AIR FILTER DESCRIPTION Fig. 2 Air Filter Door Fig. 1 Air Filter 1 2 3 4 5 6 - LOWER EVAPORATOR HOUSING - LOWER EDGE OF INSTRUMENT PANEL - AIR FILTER - INSTRUMENT PANEL CENTER FLOOR BRACKET COVER - FOAM SEAL - AIR FILTER OPENING A dust and odor air filter is standard equipment on models equipped with the dual zone or three zone temperature control systems (Fig. 1). The filter element is the same size as the front air conditioner evaporator to ensure ample filtering capacity. A removable door on the bottom of the front heater-A/C unit housing below the glove box provides easy access to the filter element for replacement. Filter replacement is recommended at 24,000 kilometer (15,000 mile) intervals. REMOVAL (1) Locate the air filter door on the bottom of the lower evaporator housing just outboard of the passenger side of the instrument panel center stack (Fig. 2). (2) Slide the air filter door latch toward the rear of the vehicle until it engages the opened stop on the door. (3) Pull the air filter door straight downward to disengage it from the air filter opening of the lower evaporator housing. (4) Use your fingers to reach through the air filter opening of the lower evaporator housing far enough to grasp the air filter. (5) Pull the air filter straight down and out of the evaporator housing (Fig. 2). 1 2 3 4 5 - AIR FILTER DOOR - LATCH - CLOSED STOP - LOWER EVAPORATOR HOUSING - OPENED STOP INSTALLATION (1) Note the “Airflow” directional arrow imprinted on the foam seal around the frame of the air filter. This arrow should always be oriented towards the center of the vehicle. (2) With the air filter “Airflow” arrow properly oriented, carefully slide the filter fully upward into the evaporator housing through the air filter opening. (3) With the latch still positioned against its opened stop, reinstall the air filter door onto the lower evaporator housing air filter opening. (4) Slide the air filter door latch toward the front of the vehicle until it hits the closed stop on the door. AIR OUTLETS DESCRIPTION Based upon the system mode selected, conditioned air can exit the front heater-A/C unit housing through one or a combination of the four main housing outlets: defrost, demist, panel, or floor. Once the conditioned air exits the unit housing, it is directed through molded plastic ducts to the various outlets in the vehicle interior. These outlets and their locations are as follows: • Defroster Outlet - A single, centrally mounted outlet delivers air for defrosting the large windshield. Because outlet vanes are not needed to direct flow, a simple, integral grid is molded into the center of the instrument panel top cover to prevent objects from falling into the duct. If the defroster outlet is faulty RS DISTRIBUTION - FRONT 24 - 41 AIR OUTLETS (Continued) or damaged, the instrument panel top cover must be replaced. • Demister Outlets - There are two side window demisters that aid in defogging and defrosting the front door windows. One demister outlet is located at each outboard end of the instrument panel top pad, near the belt line at the A-pillars. The demister outlets can be removed from the top pad individually for service replacement. • Instrument Panel Outlets - There are five panel outlets in the instrument panel, one located near each outboard end of the instrument panel facing the rear of the vehicle, and three located near the top of the instrument panel center bezel. On models with manual temperature control, all five of these outlets are fully adjustable. On models with Automatic Temperature Control (ATC), the center outlet in the center bezel has fixed vanes because it also houses the remote infrared temperature sensors for the front seat positions. The outboard outlets can be removed individually for service replacement. The center bezel outlets are serviced as a gang of three outlets and, on models with ATC, also includes the infrared sensors. • Front Door Rear Outlets - A fully adjustable outlet located at the rear of each front door trim panel supplies only cooled air to the intermediate seat passengers. Air is supplied to these outlets from the instrument panel through ducts in the doors that use molded seals at the instrument panel to prevent air leakage. The door ducts are integral to the front door trim panels. These outlets also incorporate a red reflector to improve the safety and visibility of an opened front door to traffic approaching the vehicle from the rear at night. These outlets can be removed from the door trim panels for service replacement. • Front Floor Outlets - There are two front floor outlets, one located above each side of the floor panel center tunnel below the instrument panel. These outlets are integral to the front heater-A/C unit distribution housing. • Rear Floor Outlets - Wide rear floor outlets located under each front seat have integral, fixed directional dividers to distribute heated air across the floor for intermediate seat passengers. These outlets are integral to the floor distribution ducts routed under the front floor carpet from an outlet nozzle on the bottom of the front heater-A/C unit distribution housing. REMOVAL REMOVAL - CENTER BEZEL OUTLETS The three outlets located near the top of the instrument panel center bezel are serviced only as a set of all three outlets. If the vehicle is equipped with the optional Automatic Temperature Control (ATC) system, the center outlet of the three has fixed vanes and also houses the remote front infrared temperature sensors. 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 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. (1) Disconnect and isolate the battery negative cable. (2) Remove the center bezel from the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - REMOVAL). (3) Place the center bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the center bezel from cosmetic damage. (4) If the vehicle is equipped with the optional ATC system, disconnect the ATC remote infrared temperature sensor jumper harness from the sensor connector receptacle located on the bottom of the center outlet housing (Fig. 3). (5) Remove the three screws that secure the bottom of the outlet housing to the center bezel. (6) Roll the bottom of the outlet housing upwards towards the top of the center bezel far enough to disengage the retainer features on the top of the outlet housing from their receptacles at the top of the center bezel. (7) Remove the center bezel outlets and housing from the center bezel as a unit. REMOVAL - DEMISTER OUTLET (1) Using a trim stick or another suitable wide flat-bladed tool, gently pry the outer perimeter of the demister outlet away from the instrument panel top pad until the snap features on the outlet are released (Fig. 4). (2) Remove the demister outlet from the demister duct opening in the instrument panel top pad. REMOVAL - FRONT DOOR REAR OUTLET (1) Disconnect and isolate the battery negative cable. 24 - 42 DISTRIBUTION - FRONT RS AIR OUTLETS (Continued) Fig. 3 Center Bezel Outlets 1 2 3 4 5 6 - CENTER BEZEL CENTER BEZEL OUTLETS SCREW (3) INSTRUMENT PANEL SWITCH BANK CONNECTOR (ATC ONLY) JUMPER HARHESS (ATC ONLY) Fig. 5 Front Door Rear Outlet 1 - FRONT DOOR REAR OUTLET 2 - FRONT DOOR TRIM PANEL REMOVAL - INSTRUMENT PANEL OUTLET (1) Using a trim stick or another suitable wide flat-bladed tool, gently pry the outer perimeter of the instrument panel outlet away from the instrument panel top pad until the snap features on the outlet are released (Fig. 6). Fig. 4 Demister Outlet 1 - DEMISTER OUTLET 2 - INSTRUMENT PANEL TOP PAD 3 - TRIM STICK (2) Remove the trim panel from the front door inner panel. (Refer to 23 - BODY/DOOR - FRONT/ TRIM PANEL - REMOVAL). (3) Using a trim stick or another suitable wide flat-bladed tool, depress the four latch features (two top and two bottom) that secure the outlet to the inside of the trim panel rear outlet opening and push the outlet unit out through the opening (Fig. 5). (4) Remove the front door rear outlet through the outside of the front door trim panel outlet opening. Fig. 6 Instrument Panel Outlet 1 - INSTRUMENT PANEL TOP PAD 2 - INSTRUMENT PANEL OUTLET 3 - TRIM STICK (2) Remove the instrument panel outlet from the panel duct opening in the instrument panel top pad. DISTRIBUTION - FRONT RS 24 - 43 AIR OUTLETS (Continued) INSTALLATION BLOWER MOTOR INSTALLATION - CENTER BEZEL OUTLETS DESCRIPTION (1) Position the center bezel outlets and housing onto the center bezel as a unit. (2) Engage the retainer features on the top of the outlet housing with their receptacles at the top of the center bezel, then roll the bottom of the outlet housing downwards towards the center bezel. (3) Install and tighten the three screws that secure the bottom of the outlet housing to the center bezel. Tighten the screws to 2 N·m (17 in. lbs.). (4) If the vehicle is equipped with the optional ATC system, reconnect the ATC remote infrared temperature sensor jumper harness to the sensor connector receptacle located on the bottom of the center outlet housing. (5) Reinstall the center bezel onto the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - INSTALLATION). (6) Reconnect the battery negative cable. INSTALLATION - DEMISTER OUTLET (1) Position the demister outlet over the demister duct opening in the instrument panel top pad. (2) Using hand pressure, press the demister outlet firmly and evenly into the instrument panel top pad opening until the snap features on the outlet are fully engaged. INSTALLATION - FRONT DOOR REAR OUTLET (1) Position the front door rear outlet through the outside of the front door trim panel outlet opening. (2) While keeping the outlet aligned with the door duct opening behind the trim panel, use hand pressure to press the outlet firmly and evenly through the outside of the front door trim panel outlet opening until the four latch features (two top and two bottom) that secure the outlet to the inside of the opening are fully engaged. (3) Reinstall the trim panel onto the front door inner panel. (Refer to 23 - BODY/DOOR - FRONT/ TRIM PANEL - INSTALLATION). (4) Reconnect the battery negative cable. INSTALLATION - INSTRUMENT PANEL OUTLET (1) Position the instrument panel outlet into the panel duct opening in the instrument panel top pad. (2) Using hand pressure, press the instrument panel outlet firmly and evenly into the instrument panel top pad opening until the snap features on the outlet are fully engaged. Fig. 7 Blower Motor 1 2 3 4 - BLOWER MOTOR RUBBER GROMMET BLOWER MOTOR CONNECTOR MOUNTING TABS The blower motor is a 12-volt, Direct Current (DC) motor with a squirrel cage-type blower wheel that is secured to the blower motor shaft (Fig. 7). The blower motor and wheel are located near the passenger side end of the heater-A/C unit within the two halves of the intake air housing in the passenger compartment below the instrument panel. The blower motor and blower motor wheel are a factory balanced unit and cannot be adjusted or repaired. If faulty or damaged, the blower motor and blower wheel must be replaced as a unit. OPERATION The blower motor will operate whenever the ignition switch is in the On position and the heater-A/C control power is turned on. The blower motor can only be turned off by turning off the power at the heater-A/C control. The blower motor receives battery current whenever the front blower motor relay is energized. The front blower motor relay output circuit is protected by a fuse in the Intelligent Power Module (IPM) located in the engine compartment near the battery. In the Manual system, the blower motor speed is controlled by regulating the path to ground through the blower control switch and the blower motor resistor. In the ATC system, the blower motor speed is controlled by an electronic blower power module, which uses a pulse width modulated input from the ATC module and feedback from the blower motor to regulate the blower motor ground 24 - 44 DISTRIBUTION - FRONT RS BLOWER MOTOR (Continued) path it provides. The blower motor and wheel are used to control the velocity of air moving through the heater-A/C unit housing. The blower motor controls the velocity of the air flowing through the heater-A/C housing by spinning the blower wheel within the housing at the selected speed or, in the ATC system, at the selected or programmed speed. DIAGNOSIS AND TESTING - BLOWER MOTOR BLOWER MOTOR INOPERATIVE 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 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. (1) Check the fuse (Fuse 10 - 40 ampere) in the Intelligent Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. (2) Turn the ignition switch to the On position. Be certain that the heater-A/C control power is turned on. Check for battery voltage at the fuse (Fuse 10 40 ampere) in the IPM. If OK, go to Step 3. If not OK, proceed to diagnosis of the front blower motor relay. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/BLOWER MOTOR RELAY - DIAGNOSIS AND TESTING). (3) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the front HVAC wire harness connector for the front blower motor resistor (Manual Temperature Control) or the front blower power module (Automatic Temperature Control) from the resistor or module connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the On position. Be certain that the heater-A/C control power is turned on. Check for battery voltage at the fused front blower motor relay output circuit cavity of the front HVAC wire harness connector for the front blower motor resistor (MTC) or the front blower power module (ATC). If OK, go to Step 4. If not OK, repair the open fused front blower motor relay output circuit to the IPM as required. (4) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the front blower motor pigtail wire connector from the connector receptacle of the front blower motor resistor (MTC) or the front blower power module (ATC). Use jumper wires to connect a battery and ground feeds to the blower motor pigtail wire connector. The blower motor should operate. If OK with MTC, proceed to diagnosis of the front blower motor resistor. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/BLOWER MOTOR RESISTOR - DIAGNOSIS AND TESTING). If OK with ATC, use a DRBIII scan tool to diagnose the front blower power module. Refer to the appropriate diagnostic information. If not OK with MTC or ATC, replace the faulty front blower motor. BLOWER MOTOR NOISE OR VIBRATION Refer to the Blower Motor Noise/Vibration Diagnosis chart (Fig. 8). REMOVAL The blower motor and blower wheel are serviced only as a balanced unit. If either component is faulty or damaged, the entire unit must be replaced. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). (1) Disconnect the blower motor pigtail harness connector from the connector receptacle of either the blower motor resistor or power module, depending how vehicle is equipped (Fig. 9). (2) Remove the lower right trim panel and roll back the carpet. (3) Remove the two screws that secure the recirculation door actuator and disengage the wire harness from the routing clips molded into the bottom of the lower air intake housing. (4) Remove the one screw (from the top) that secures the lower air intake housing to the upper air intake housing. (5) Remove the four screws (from the bottom) that secures the lower air intake housing to the lower half of the evaporator housing and the upper air intake housing. (6) Push the rubber grommet on the blower motor pigtail wires through the hole in the lower intake air housing (Fig. 10). DISTRIBUTION - FRONT RS BLOWER MOTOR (Continued) Fig. 8 Blower Motor Noise/Vibration Diagnosis 24 - 45 24 - 46 DISTRIBUTION - FRONT RS BLOWER MOTOR (Continued) the blower motor to the blower housing in the lower half of the evaporator housing (Fig. 11). Fig. 11 Blower Motor Mounting Tabs Fig. 9 Lower Intake Air Housing 1 2 3 4 5 6 7 8 - LOWER INTAKE AIR HOUSING RECIRCULATION AIR DOOR ACTUATOR BLOWER MOTOR PIGTAIL WIRE CONNECTOR RUBBER GROMMET BLOWER MOTOR RESISTOR/POWER MODULE LOWER EVAPORATOR HOUSING UPPER INTAKE AIR HOUSING RECIRCULATION AIR DOOR 1 2 3 4 - BLOWER MOTOR RUBBER GROMMET BLOWER MOTOR CONNECTOR MOUNTING TABS (9) Gently flex the recirculation air door far enough to remove the blower motor and blower wheel from the blower housing in the lower half of the evaporator housing. INSTALLATION The blower motor and blower wheel are serviced only as a balanced unit. If either component is faulty or damaged, the entire unit must be replaced. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). Fig. 10 Rubber Grommet - Typical 1 - BLOWER MOTOR PIGTAIL WIRE GROMMET (7) Feed the blower motor pigtail wires and electrical connector through the grommet hole in the lower intake air housing. (8) Relocate the recirculation air door as necessary to access and remove the three screws that secure (1) Gently flex the recirculation air door far enough to position the blower motor and blower wheel into the blower housing in the lower half of the evaporator housing. (2) Install and tighten the four screws that secure the blower motor to the blower housing in the lower half of the evaporator housing. Tighten the screws to 2 N·m (18 in. lbs.). (3) Feed the blower motor pigtail wires and electrical connector through the grommet hole in the lower intake air housing and seat the rubber grommet. DISTRIBUTION - FRONT RS 24 - 47 BLOWER MOTOR (Continued) (4) Position the upper pivot of the recirculation door into the opening at the top of the air inlet housing an dhold in place while the lower air inlet housing is placed in position. (5) Install and tighten the three screws (from the bottom) that secure the lower air intake housing to the lower half of the evaporator housing. Tighten the screws to 2 N·m (18 in. lbs.). (6) Install and tighten the one screw that secures the upper intake air housing to the lower intake air housing. Tighten the screws to 2 N·m (18 in. lbs.). (7) Install the recirculation actuator making certain that the splines are aligned and secure the actuator with two screws and torque the to 2 N·m (18 in. lbs.). Route the wiring into the molded inn routing clips. (8) Position the carpet into location and install the lower right trim panel. (9) Connect the blower motor pigtail wire harness electrical connector back into either the power module or resistor receptacle. (10) Run the Heater-A/C Calibration procedure(Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL - STANDARD PROCEDURE). (11) Run the HVAC Control Cooldown test(Refer to 24 - HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING). DEFROSTER DUCT 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 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. (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument panel from the vehicle. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL). (3) Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. (4) Remove the fasteners that secure the defroster duct to the instrument panel armature. (5) Remove the defroster duct from the instrument panel. INSTALLATION 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 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. (1) Position the defroster duct to the instrument panel. (2) Install the fasteners that secure the defroster duct to the instrument panel armature. (3) Reinstall the instrument panel in the vehicle. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION). (4) Reconnect the battery negative cable. DEMISTER DUCTS 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 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. (1) Disconnect and isolate the battery negative cable. 24 - 48 DISTRIBUTION - FRONT RS DEMISTER DUCTS (Continued) (2) Remove the instrument panel from the vehicle. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL). (3) Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. (4) Remove the fasteners that secure the demister ducts to the instrument panel armature. (5) Disengage the demister ducts from the demister outlets. (6) Remove the demister ducts from the instrument panel. INSTALLATION 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 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. (1) Position the demister ducts to the instrument panel. (2) Engage the demister ducts to the demister outlets. (3) Install the fasteners that secure the demister ducts to the instrument panel armature. (4) Reinstall the instrument panel into the vehicle. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION). (5) Reconnect the battery negative cable. FLOOR DISTRIBUTION DUCTS REMOVAL (1) Roll back the carpet on the front floor from under the instrument panel toward the rear of the vehicle. (Refer to 23 - BODY/INTERIOR/CARPETS AND FLOOR MATS - REMOVAL). (2) Lift the center floor distribution duct upward far enough to disengage its locator hole from the weld stud on the front floor panel (Fig. 12). (3) Pull the floor distribution duct assembly rearward far enough to disengage the center floor distri- Fig. 12 Floor Distribution Ducts 1 2 3 4 - CENTER FLOOR DISTRIBUTION DUCT RIGHT FLOOR DISTRIBUTION DUCT LEFT FLOOR DISTRIBUTION DUCT WELD STUD bution duct from the outlet on the bottom of the heater-A/C housing unit. (4) Disassemble the right and/or left floor distribution ducts from the center floor distribution duct as required. INSTALLATION (1) Assemble the right and/or left floor distribution ducts onto the center floor distribution duct as required. (2) Slide the floor distribution duct assembly under the instrument panel center stack far enough to engage the center floor distribution duct with the outlet on the bottom of the heater-A/C housing unit. (3) Align the locator hole on the center floor distribution duct with the weld stud on the front floor panel. (4) Using hand pressure, push the locator hole of the center floor distribution duct down over the weld stud on the front floor panel. (5) Reinstall the carpet onto the front floor panel and under the instrument panel. (Refer to 23 BODY/INTERIOR/CARPETS AND FLOOR MATS INSTALLATION). DISTRIBUTION - FRONT RS 24 - 49 HVAC HOUSING REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). 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 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. (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). (2) Drain the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN). (3) Disconnect and isolate the battery negative cable. (4) Disconnect the liquid line and suction line from the expansion valve. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/LIQUID LINE - REMOVAL) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/SUCTION LINE - REMOVAL). (5) Disconnect the heater hoses from the heater core tubes. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER HOSE REMOVAL). (6) Remove the four nuts that secure the heaterA/C unit housing studs to the engine compartment side of the dash panel (Fig. 13). (7) Remove the instrument panel from the passenger compartment. (Refer to 23 - BODY/INSTRU- Fig. 13 Heater-A/C Unit Housing Studs 1 2 3 4 - HEATER-A/C UNIT HOUSING DASH PANEL NUT (4) STUD (4) MENT PANEL/INSTRUMENT PANEL ASSEMBLY REMOVAL). (8) Remove the floor distribution duct from the heater-A/C unit housing. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/ FLOOR DISTRIBUTION DUCTS - REMOVAL). (9) Remove the one screw that secures the heaterA/C unit housing bracket to the passenger compartment side of the dash panel (Fig. 14). Fig. 14 Heater-A/C Unit Housing 1 2 3 4 - HEATER-A/C UNIT HOUSING SCREW BRACKET DASH PANEL 24 - 50 DISTRIBUTION - FRONT RS HVAC HOUSING (Continued) (10) Pull the heater-A/C unit housing rearward far enough for the mounting studs to clear the dash panel and remove the unit from the passenger compartment. INSTALLATION (1) Position the heater-A/C unit housing against the dash panel in the passenger compartment with the four mounting studs located in their proper mounting holes in the dash panel. (2) Install and tighten the one screw that secures the heater-A/C unit housing bracket to the passenger compartment side of the dash panel. Tighten the screw to 3 N·m (26 in. lbs.). (3) Install and tighten the four nuts that secure the heater-A/C unit housing studs to the engine compartment side of the dash panel. Tighten the nuts to 7 N·m (62 in. lbs.). (4) Reinstall the floor distribution duct onto the heater-A/C unit housing. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/ FLOOR DISTRIBUTION DUCTS - INSTALLATION). (5) Reinstall the instrument panel into the passenger compartment. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY INSTALLATION). (6) Reconnect the heater hoses to the heater core tubes. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER HOSE INSTALLATION). (7) Reconnect the suction line and liquid line to the expansion valve. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/SUCTION LINE - INSTALLATION) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/ LIQUID LINE - INSTALLATION). (8) Reconnect the battery negative cable. (9) Refill the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). (10) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (11) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). PANEL DUCTS 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 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. (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument panel from the vehicle. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL). (3) Place the instrument panel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the instrument panel from cosmetic damage. (4) Remove the fasteners that secure the panel ducts to the instrument panel armature. (5) Disengage the panel ducts from the panel outlets. (6) Remove the panel ducts from the instrument panel. INSTALLATION (1) Position the panel ducts to the instrument panel. (2) Engage the panel ducts to the panel outlets. (3) Install the fasteners that secure the panel ducts to the instrument panel armature. (4) Reinstall the instrument panel into the vehicle. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION). (5) Reconnect the battery negative cable. DISTRIBUTION - REAR RS 24 - 51 DISTRIBUTION - REAR TABLE OF CONTENTS page AIR OUTLETS DESCRIPTION . . . . . . REMOVAL . . . . . . . . . . INSTALLATION . . . . . . A/C DISTRIBUTION DUCT REMOVAL . . . . . . . . . . INSTALLATION . . . . . . BLOWER MOTOR DESCRIPTION . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 . . . . . . . . . . . . . . . . . . . 51 . . . . . . . . . . . . . . . . . . . 51 . . . . . . . . . . . . . . . . . . . 52 . . . . . . . . . . . . . . . . . . . 52 . . . . . . . . . . . . . . . . . . . 52 . . . . . . . . . . . . . . . . . . . 52 page DIAGNOSIS AND TESTING - BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . REAR HEATER-A/C HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . REAR HEATER DISTRIBUTION DUCT REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53 . . . . . . . . 53 . . . . . . . . 55 . . . . . . . . 55 . . . . . . . . 56 . . . . . . . . 58 . . . . . . . . 58 AIR OUTLETS DESCRIPTION Based upon the system mode selected, conditioned air can exit the rear heater-A/C unit housing through one or a combination of the two main housing outlets: air conditioner, or heater. Once the conditioned air exits the unit housing, it is directed through molded plastic ducts to the various outlets in the vehicle interior. These outlets and their locations are as follows: • Floor Outlets - Three floor outlets with fixed vanes are located in the right quarter trim panel, near the floor. These outlets distribute air from the rear heater distribution duct to the intermediate and rear seat occupants. The floor outlets are integral to the right quarter trim panel and, if faulty or damaged, the quarter trim panel must be replaced. • Overhead Outlets - Four (two right side and two left side) fully adjustable outlets along the roof rails distribute air from the rear A/C distribution duct and the headliner ducts to the intermediate and rear seat occupants. The headliner ducts are integral to the headliner panel. Each overhead outlet is housed in a headliner bezel. The two forward headliner bezels also feature a courtesy lamp, a fold-away coat hook, and a fold-away assist handle. The overhead outlets can be removed from the headliner bezels individually for service replacement. (2) Pull the opposite end of the overhead outlet away from its pivot pin in the headliner bezel until that end of the outlet is released. (3) Remove the overhead outlet from the opening in the headliner bezel. REMOVAL INSTALLATION (1) Using a trim stick or another suitable wide flat-bladed tool, gently pry the thumb wheel end of the overhead outlet away from the pivot pin in the headliner bezel until one end of the outlet is released (Fig. 1). Fig. 1 Overhead Outlet 1 2 3 4 5 6 - HEADLINER BEZEL - OVERHEAD OUTLET - TRIM STICK - COURTESY LAMP - COAT HOOK - ASSIST HANDLE (1) Position the overhead outlet into the opening in the headliner bezel. (2) Slide the non-thumb wheel end of the outlet onto the pivot pin in the headliner bezel. Using hand pressure, push the thumb wheel end outboard onto the pivot pin until it fully seats. 24 - 52 DISTRIBUTION - REAR RS A/C DISTRIBUTION DUCT BLOWER MOTOR REMOVAL DESCRIPTION (1) Remove the trim from the right quarter inner panel and the right D pillar. (Refer to 23 - BODY/INTERIOR/RIGHT QUARTER TRIM PANEL REMOVAL). (2) Slide the rear air conditioning distribution duct upwards far enough to disengage it from the outlet at the top of the rear heater-A/C unit housing (Fig. 2). Fig. 2 Rear A/C Distribution Duct 1 - HEADLINER DUCT 2 - REAR A/C DISTRIBUTION DUCT 3 - REAR HEATER-A/C UNIT OUTLET (3) While pulling the lower end of the auxiliary air conditioning distribution duct away from the rear heater-A/C unit outlet, disengage the upper end of the distribution duct from the headliner duct. (4) Remove the auxiliary air conditioning distribution duct from the vehicle. INSTALLATION (1) Align the upper end of the rear air conditioning distribution duct to the headliner duct. (2) Slide the upper end of the rear air conditioning distribution duct onto the headliner duct far enough to align the lower end of the duct with the outlet at the top of the rear heater-A/C unit housing. (3) Slide the rear air conditioning distribution duct downwards far enough to engage it onto the outlet at the top of the rear heater-A/C unit housing. (4) Reinstall the trim onto the right quarter inner panel and the right D pillar. (Refer to 23 - BODY/INTERIOR/RIGHT QUARTER TRIM PANEL INSTALLATION). Fig. 3 Blower Motor 1 2 3 4 - REAR HEATER-A/C UNIT HOUSING BLOWER MOTOR SCREW (3) BLOWER PIGTAIL WIRE The blower motor is a 12-volt, Direct Current (DC) motor with a squirrel cage-type blower wheel that is secured to the blower motor shaft (Fig. 3). The blower motor and wheel are located in a housing near the top of the rear heater-A/C unit in the passenger compartment behind the right rear wheel house. The rear heater-A/C unit housing must be removed from the vehicle to access the blower motor and blower wheel for service. The blower motor and blower motor wheel are a factory balanced unit and cannot be adjusted or repaired. If faulty or damaged, the blower motor and blower wheel must be replaced as a unit. OPERATION The rear blower motor will operate whenever the ignition switch is in the On position, the heater-A/C control power is turned on, and the rear heater-A/C DISTRIBUTION - REAR RS 24 - 53 BLOWER MOTOR (Continued) system control switch on the front heater-A/C control is not in the Off position. The blower motor can only be turned off by turning off the rear system at the front heater-A/C control. The blower motor receives battery current whenever the rear blower motor relay is energized. The rear blower motor relay output circuit is protected by a fuse in the Intelligent Power Module (IPM) located in the engine compartment near the battery. In the MTC system, the blower motor speed is controlled by regulating the path to ground through the blower control switch and the blower motor resistor. In the ATC system, the blower motor speed is controlled by an electronic blower power module, which uses a pulse width modulated input from the ATC module and feedback from the blower motor to regulate the blower motor ground path it provides. The blower motor and wheel are used to control the velocity of air moving through the rear heater-A/C unit housing. The blower motor controls the velocity of the air flowing through the rear heater-A/C housing by spinning the blower wheel within the housing at the selected speed or, in the ATC system, at the selected or programmed speed. DIAGNOSIS AND TESTING - BLOWER MOTOR BLOWER MOTOR INOPERATIVE (1) Check the fuse (Fuse 12 - 25 ampere) in the Intelligent Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. (2) Turn the ignition switch to the On position. Be certain that the rear heater-A/C control power is turned on. Check for battery voltage at the fuse (Fuse 12 - 25 ampere) in the IPM. If OK, go to Step 3. If not OK, proceed to diagnosis of the rear blower motor relay. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - REAR/BLOWER MOTOR RELAY - DIAGNOSIS AND TESTING). (3) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the rear HVAC wire harness connector for the rear blower motor resistor (Manual Temperature Control) or the rear blower power module (Automatic Temperature Control) from the resistor or module connector receptacle. Reconnect the battery negative cable. Turn the ignition switch to the On position. Be certain that the rear heater-A/C control power is turned on. Check for battery voltage at the fused rear blower motor relay output circuit cavity of the rear HVAC wire harness connector for the rear blower motor resistor (MTC) or the rear blower power module (ATC). If OK, go to Step 4. If not OK, repair the open fused front blower motor relay output circuit to the IPM as required. (4) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the rear blower motor pigtail wire connector from the take out and connector of the rear HVAC wire harness (MTC) or the connector receptacle of the rear blower power module (ATC). Use jumper wires to connect a battery and ground feeds to the blower motor pigtail wire connector. The blower motor should operate. If OK with MTC, proceed to diagnosis of the rear blower motor resistor. (Refer to 24 - HEATING & AIR CONDITIONING/ CONTROLS - REAR/BLOWER MOTOR RESISTOR DIAGNOSIS AND TESTING). If OK with ATC, use a DRBIII scan tool to diagnose the rear blower power module. Refer to the appropriate diagnostic information. If not OK with MTC or ATC, replace the faulty rear blower motor. BLOWER MOTOR NOISE OR VIBRATION Refer to the Blower Motor Noise/Vibration Diagnosis chart (Fig. 4). REMOVAL The rear blower motor and blower wheel are serviced only as a balanced unit. If either component is faulty or damaged, the entire unit must be replaced. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). (1) Remove the rear heater-A/C unit housing from the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR HEATERA/C HOUSING - REMOVAL). (2) Disconnect the rear blower motor pigtail wire connector. With manual temperature control, the blower pigtail wire is connected to a take out and connector of the rear HVAC wire harness. With automatic temperature control, the blower pigtail wire is connected to a receptacle on the blower power module. (3) Remove the three screws that secure the blower motor to the outboard side of the rear heaterA/C unit housing (Fig. 5). (4) Remove the blower motor and blower wheel from the rear heater-A/C unit housing. 24 - 54 DISTRIBUTION - REAR BLOWER MOTOR (Continued) Fig. 4 Blower Motor Noise/Vibration Diagnosis RS DISTRIBUTION - REAR RS 24 - 55 BLOWER MOTOR (Continued) REAR HEATER-A/C HOUSING REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). Fig. 5 Blower Motor 1 2 3 4 - REAR HEATER-A/C UNIT HOUSING BLOWER MOTOR SCREW (3) BLOWER PIGTAIL WIRE (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). (2) Drain the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN). (3) Disconnect and isolate the battery negative cable. (4) Raise and support the vehicle. (5) Disconnect the underbody refrigerant line sealing plate from the rear heater-A/C unit evaporator extension line sealing plate that extends through the rear floor panel behind the right rear wheel housing (Fig. 6). INSTALLATION (1) Position the blower motor and blower wheel onto the outboard side of the rear heater-A/C unit housing. (2) Install and tighten the three screws that secure the blower motor to the rear heater-A/C unit housing. Tighten the screws to 2 N·m (18 in. lbs.). (3) Reconnect the rear blower motor pigtail wire connector. With manual temperature control, the blower pigtail wire is connected to a take out and connector of the rear HVAC wire harness. With automatic temperature control, the blower pigtail wire is connected to a receptacle on the blower power module. (4) Reinstall the rear heater-A/C unit housing into the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR HEATERA/C HOUSING - INSTALLATION). Fig. 6 Refrigerant Lines 1 - UNDERBODY REFRIGERANT LINE SEALING PLATE (6) Remove the seals from the liquid line and suction line fittings and discard. (7) Install plugs in, or tape over the opened liquid line and suction line fittings and both ports in the evaporator extension line sealing plate. 24 - 56 DISTRIBUTION - REAR RS REAR HEATER-A/C HOUSING (Continued) (8) Remove the three nuts that secure the rear heater-A/C unit mounting studs to the rear floor panel behind the right rear wheel housing (Fig. 7). Fig. 7 Rear Heater-A/C Unit Mounting Studs (18) Install plugs in, or tape over the opened heater core fittings and both heater hoses. (19) Use absorbent toweling to mop up any engine coolant spills from the preceding operation. (20) Remove the screw that secures the back of the rear heater-A/C unit housing to the right D-pillar (Fig. 8). (21) Remove the screw that secures the front of the rear heater-A/C unit housing to the right quarter inner panel. (22) Lift the rear heater-A/C unit housing up far enough for the lower mounting studs and the evaporator extension lines to clear the mounting holes in the rear floor panel. (23) Remove the rear heater-A/C unit housing from the vehicle. (24) Use absorbent toweling to mop up any engine coolant spills from the preceding operation. INSTALLATION 1 - REAR HEATER-A/C UNIT MOUNTING STUDS (9) Lower the vehicle. (10) Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL). (11) Remove the rear A/C distribution duct from the rear heater-A/C unit and the rear roof duct. (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION - REAR/AUXILIARY A/C DISTRIBUTION DUCT - REMOVAL). (12) Disconnect the body wire harness connector for the rear heater-A/C unit housing from the rear HVAC wire harness connector located near the expansion valve at the back of the unit. (13) Remove the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. (14) Remove the two screws that secure the bottom of the quarter trim panel attaching bracket to the rear heater-A/C unit housing. (15) Remove the rear heater distribution duct from the right quarter inner panel. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/REAR HEATER DISTRIBUTION DUCT REMOVAL). (16) Take the proper precautions to protect the carpeting below the rear heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. (17) Disconnect the heater hoses at the rear heater core. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - REMOVAL). NOTE: If the rear heater core or the rear heater-A/C housing have been removed from the vehicle for service, the rear heater core may be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - REAR/HEATER CORE - STANDARD PROCEDURE - HEATER CORE FILLING). (1) Position the rear heater-A/C unit housing into the vehicle with the evaporator extension line sealing plate inserted into the rectangular hole in the rear floor panel behind the right rear wheel house. (2) Align the rear heater-A/C unit housing lower mounting studs with the mounting holes in the rear floor panel and lower the unit to the floor. (3) Install and tighten the screw that secures the front of the rear heater-A/C unit housing to the right quarter inner panel. Tighten the screw to 11 N·m (97 in. lbs.). (4) Install and tighten the screw that secures the back of the rear heater-A/C unit housing to the right D-pillar. Tighten the screw to 11 N·m (97 in. lbs.). (5) Remove the plugs or tape from both heater core fittings and both heater hoses. (6) Reconnect the heater hoses to the rear heater core. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - INSTALLATION). (7) Reinstall the rear heater distribution duct onto the right quarter inner panel. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/REAR HEATER DISTRIBUTION DUCT INSTALLATION). DISTRIBUTION - REAR RS 24 - 57 REAR HEATER-A/C HOUSING (Continued) Fig. 8 Rear Heater-A/C Housing 1 2 3 4 - U-NUT (3) REAR HEATER-A/C HOUSING SCREW (3) EXPANSION VALVE (8) Install and tighten the two screws that secure the bottom of the quarter trim panel attaching bracket to the rear heater-A/C unit housing. Tighten the screws to 1.7 N·m (15 in. lbs.). (9) Install and tighten the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. (10) Reconnect the body wire harness connector for the rear heater-A/C unit housing to the rear HVAC wire harness connector located near the expansion valve at the back of the unit. (11) Reinstall the auxiliary A/C distribution duct onto the rear heater-A/C unit and the rear roof duct. (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION - REAR/AUXILIARY A/C DISTRIBUTION DUCT - INSTALLATION). (12) Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION). (13) Raise and support the vehicle. 5 6 7 8 - STUD (3) HEATER LINES NUT (5) STUD (2) (14) Install and tighten the three nuts that secure the rear heater-A/C unit mounting studs to the rear floor panel behind the right rear wheel housing. Tighten the nuts to 9 N·m (80 in. lbs.). (15) Remove the tape or plugs from the underbody liquid line and suction line fittings and both ports in the rear heater-A/C unit evaporator extension line sealing plate that extends through the rear floor panel behind the right rear wheel housing. (16) Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the liquid line and suction line fittings. (17) Reconnect the underbody refrigerant line sealing plate to the evaporator extension line sealing plate. (18) Install and tighten the screw that secures the underbody refrigerant line sealing plate to the evaporator extension line sealing plate. Tighten the screw to 23 N·m (17 ft. lbs.). (19) Lower the vehicle. (20) Reconnect the battery negative cable. 24 - 58 DISTRIBUTION - REAR RS REAR HEATER-A/C HOUSING (Continued) (21) Refill the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). (22) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (23) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). (24) Run the HVAC Cooldown test to verify proper operation(Refer to 24 - HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING). REAR HEATER DISTRIBUTION DUCT REMOVAL (1) Remove the trim from the right quarter inner panel. (Refer to 23 - BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - REMOVAL). (2) Remove the two screws that secure the rear heater distribution duct to the right quarter inner panel (Fig. 9). (3) Slide the rear heater distribution duct forward far enough to disengage it from the outlet on the front of the rear heater-air conditioner unit housing. (4) Remove the rear heater distribution duct from the vehicle. INSTALLATION (1) Align the inlet end of rear heater distribution duct with the outlet on the front of the rear heaterair conditioner unit housing. Fig. 9 Rear Heater Distribution Duct 1 - REAR HEATER DISTRIBUTION DUCT 2 - REAR HEATER-A/C UNIT OUTLET 3 - SCREW (2) (2) Slide the rear heater distribution duct rearward far enough to fully engage the inlet end of the duct with the outlet on the front of the rear heaterair conditioner unit housing. (3) Install and tighten the two screws that secure the rear heater distribution duct to the right quarter inner panel. Tighten the screws to 1.6 N·m (14 in. lbs.). (4) Reinstall the trim onto the right quarter inner panel. (Refer to 23 - BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - INSTALLATION). PLUMBING - FRONT RS 24 - 59 PLUMBING - FRONT TABLE OF CONTENTS page PLUMBING - FRONT WARNING WARNING . . . . . . . . . . . . . . . . . . . . . . . . WARNING . . . . . . . . . . . . . . . . . . . . . . . . WARNING - A/C PLUMBING . . . . . . . . . . CAUTION - A/C PLUMBING ............ COMPRESSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - COMPRESSOR NOISE DIAGNOSIS . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - COMPRESSOR . . . . . . . . . . REMOVAL - COMPRESSOR MOUNTING BRACKET - 2.4L ENGINE . . . . . . . . . . . . INSTALLATION INSTALLATION - COMPRESSOR . . . . . . . INSTALLATION - COMPRESSOR MOUNTING BRACKET - 2.4L ENGINE . . . CONDENSER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . DISCHARGE LINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . EVAPORATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . EXPANSION VALVE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . HEATER CORE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL- HEATER CORE EXTENSION TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - HEATER CORE . . . . . . . . . . INSTALLATION INSTALLATION- HEATER CORE EXTENSION TUBES . . . . . . . . . . . . . . . . INSTALLATION - HEATER CORE . . . . . . . . . . . . . . . . 60 . 60 . 60 . 61 . . . 62 . . . 62 . . . 62 . . . 63 . . . 64 . . . 64 . . . 65 . . . . . . . . . 65 . 65 . 65 . 66 . . . 67 . . . 68 . . . . . . . . . 68 . 68 . 69 . 70 . . . 71 . . . 71 . . . 71 . . . 72 . . . 73 . . . 73 . . . 73 . . . 74 . . . 75 . . . 76 . . . 77 page HEATER HOSE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . HEATER HOSES - DIESEL SUPPLEMENTAL HEATER - BUX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . HEATER PIPES - DIESEL SUPPLEMENTAL HEATER - BUX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . LIQUID LINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . RECEIVER/DRIER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERANT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL 2.5L DIESEL . . . . STANDARD PROCEDURE STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT . . . . . . . . . STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERANT OIL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . SUCTION LINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . SERVICE PORTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78 . 79 . 80 . 80 . 80 . 82 . 82 . 84 . 85 . 85 . 85 . 86 . 87 . 87 . 87 . 88 . 89 . 90 . 91 . 92 . 93 . 93 . 93 . 93 . 94 . 95 . 95 . 96 24 - 60 PLUMBING - FRONT RS WARNING DEALER OR A LOCAL GOVERNMENT AGENCY FOR THE LOCATION OF AN APPROVED ETHYLENE GLYCOL COLLECTION AND/OR RECYCLING CENTER IN YOUR AREA. WARNING WARNING - A/C PLUMBING WARNING: DO NOT OPERATE DCHA IN AN ENCLOSED AREA SUCH AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE DCHA’S EXHAUST WHEN OPERATING THE DCHA. FAILURE TO FOLLOW THESE INSTRUCTION MAY RESULT IN PERSONAL INJURY OR DEATH. ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MY RESULT IN PERSONAL INJURY. VERIFY THAT ALL DCHA FUEL LINES ARE SECURELY FASTENED TO THEIR RESPECTIVE COMPONENTS BEFORE THIS PROCEDURE. WARNING:: THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. PLUMBING - FRONT WARNING WARNING:: THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES OF 97 TO 123 KILOPASCALS (14 TO 18 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 SYSTEM IS HOT AND UNDER PRESSURE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 MINUTES BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. WARNING: THE ENGINE COOLING SYSTEM CONTAINS ANTIFREEZE. ANTIFREEZE IS AN ETHYLENE GLYCOL BASED COOLANT AND IS HARMFUL IF SWALLOWED OR IF THE VAPORS ARE INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF VAPORS ARE INHALED, MOVE TO AN AREA FOR FRESH AIR. 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. WARNING: DISPOSE OF ETHYLENE GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR 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 AIR CONDITIONING 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. WARNING: IF ACCIDENTAL 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. 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 INJURY OR PROPERTY DAMAGE. RS PLUMBING - FRONT 24 - 61 PLUMBING - FRONT (Continued) CAUTION - A/C PLUMBING CAUTION:: Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with the service equipment being used. CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Damage to the system will result. CAUTION: R-12 refrigerant oil must not be mixed with R-134a refrigerant oil. They are not compatible. CAUTION: Do not use R-12 equipment or parts on the R-134a system. Damage to the system will result. All parts, tools, and equipment must be designed for R-134a refrigerant. CAUTION: Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. CAUTION: The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. CAUTION: The refrigerant system must always be evacuated before charging. CAUTION: Do not overcharge the refrigerant system. This will cause excessive compressor head pressure and can cause noise and system failure. CAUTION: Do not open the refrigerant system or remove the sealing caps from a replacement component until it is to be installed. This will prevent contamination in the system. CAUTION: Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. CAUTION: When it is necessary to open the refrigerant system, have everything needed to service the system ready. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug to prevent the entrance of dirt and moisture. The refrigerant system should not be left open to the atmosphere any longer than necessary. CAUTION: Before connecting an open refrigerant fitting, always install a new seal or gasket. All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. Coat the fitting and seal with clean refrigerant oil before connecting. Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. CAUTION: When installing a refrigerant line, avoid sharp bends that may restrict refrigerant flow. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. CAUTION: Position the refrigerant lines away from exhaust system components or any sharp edges, which may damage the line. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. Inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. CAUTION: High pressures are produced in the refrigerant system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. CAUTION: Tighten refrigerant fittings only to the specified torque. The aluminum fittings used in the refrigerant system will not tolerate overtightening. CAUTION: When disconnecting a refrigerant fitting, use a wrench on both halves of the fitting. This will prevent twisting of the refrigerant lines or tubes. 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. 24 - 62 PLUMBING - FRONT RS PLUMBING - FRONT (Continued) CAUTION: All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry. Keep the work area clean. Contamination of the refrigerant system through careless work habits must be avoided. The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is introduced to the refrigerant system. COMPRESSOR DESCRIPTION The compressor used on this vehicle can be one of two models, depending upon the air conditioning system in the vehicle. All vehicles use the Nippondenso 10S20 compressor. This compressor use an aluminum swash plate, teflon coated pistons and aluminum sleeveless cylinder walls. This compressor includes an integral high pressure relief valve. The compressor is secured low in the right front corner of the engine compartment to a mounting bracket on the cylinder block (2.4L engine), or directly to the cylinder block (3.3L and 3.8L engines) is integral to the compressor. This compressor cannot be repaired. If faulty or damaged, the entire compressor must be replaced. The compressor clutch, pulley, and clutch coil are available for service replacement. OPERATION The compressor is driven by the engine through an electric clutch, drive pulley and belt arrangement. The compressor is lubricated by refrigerant oil that is circulated throughout the refrigerant system with the refrigerant. The compressor draws in low-pressure refrigerant vapor from the evaporator through its suction port. It then compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor. The compressor pumps high-pressure refrigerant vapor to the condenser through the compressor discharge port. The mechanical high pressure relief valve is designed to vent refrigerant from the system to protect against damage to the compressor or other system components, caused by condenser air flow restrictions or an overcharge of refrigerant. The valve only vents enough refrigerant to reduce the system pressure, then re-seats itself. The valve opens at a discharge pressure of 3445 to 4135 kPA (500 to 600 psi) or above, and closes when a minimum discharge pressure of 2756 kPa (400 psi) is reached. DIAGNOSIS AND TESTING - COMPRESSOR NOISE DIAGNOSIS Excessive noise while the air conditioning compressor is operating can be caused by loose compressor mounts, a loose compressor clutch, or high operating pressures in the refrigerant system. Verify compressor drive belt condition, proper compressor mounting, correct refrigerant charge level, and compressor head pressure before compressor repair is performed. With the close tolerances within the compressor, it is possible to experience a temporary lockup. The longer the compressor is inactive, the more likely the condition is to occur. This condition is the result of normal refrigerant migration within the refrigerant system caused by ambient temperature changes. The refrigerant migration may wash the refrigerant oil out of the compressor. NOTE: Prior to a vehicle being removed from service or stored for more than two weeks, the compressor should be operated to ensure adequate refrigerant oil distribution throughout the system components. Turn on the air conditioner for a minimum of five minutes with outside air and the highest blower speed selected. BELT NOISE If the compressor drive belt slips at initial start-up, it does not necessarily mean the compressor has failed. The following procedure can be used to identify a compressor drive belt noise problem. • Start the vehicle and run at idle. • Turn the air conditioner On and listen for belt squeal. • If belt squeal is heard, turn the air conditioner Off immediately. If the belt squeal stops when the air conditioner is turned Off, perform the following repair procedures. (1) Using an appropriate sized oil filter wrench or a strap wrench, grasp the outer diameter of the compressor clutch hub. While facing the compressor, rotate the hub clockwise, then counterclockwise. If the hub rotates, proceed to the next step. If the hub will not rotate, the compressor is internally damaged, and must be replaced. (2) Turn the hub clockwise five complete revolutions and remove the tool. (3) Start the vehicle and run at idle. (4) Turn the air conditioner On. Observe the compressor and the system for normal operation, noting cooling performance and noise levels. Operate for five minutes before turning the air conditioner Off. If acceptable cooling performance is observed during compressor operation, the compressor does not need to be replaced. PLUMBING - FRONT RS 24 - 63 COMPRESSOR (Continued) (5) Inspect the drive belt for wear, damage, and proper tension. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - DIAGNOSIS AND TESTING). REMOVAL REMOVAL - COMPRESSOR WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). (2) Disconnect and isolate the battery negative cable. (3) Remove the nut that secures the suction line fitting to the top of the compressor. (4) Disconnect the suction line fitting from the compressor suction port. (5) Remove the seal from the suction line fitting and discard. (6) Install plugs in, or tape over the opened suction line fitting and the compressor suction port. (7) Remove the nut that secures the discharge line fitting to the top of the compressor. (8) Disconnect the discharge line fitting from the compressor discharge port. (9) Remove the seal from the discharge line fitting and discard. (10) Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port. (11) Raise and support the vehicle. (12) Remove the serpentine accessory drive belt from the front of the engine. (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - 2.4L REMOVAL) or (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - 3.3L/3.8L - REMOVAL). (13) Disconnect the engine wire harness connector for the compressor clutch coil from the coil pigtail wire connector on the top of the compressor (Fig. 1) or (Fig. 2). (14) On models with the 3.3L and 3.8L engines, disengage the retainer on the engine wire harness compressor clutch coil take out from the bracket on the top of the compressor. Fig. 1 Compressor - 2.4L Engine 1 2 3 4 5 6 - CLUTCH COIL CONNECTOR DISCHARGE PORT COMPRESSOR SUCTION PORT SCREW (4) COMPRESSOR MOUNTING BRACKET 1 2 3 4 5 6 7 8 - STUD CLUTCH COIL CONNECTOR DISCHARGE PORT SCREW (2) SUCTION PORT COMPRESSOR SCREW NUT Fig. 2 Compressor - 3.3L/3.8L Engine (15) On models with the 2.4L engine, remove the four screws that secure the compressor to the mounting bracket on the engine. (16) On models with the 3.3L and 3.8L engines, remove the three screws and one nut that secure the compressor to the engine. 24 - 64 PLUMBING - FRONT RS COMPRESSOR (Continued) (17) Remove the compressor from the engine compartment. NOTE: If a replacement compressor is being installed, be certain to drain and measure the refrigerant oil contained in the removed compressor. This will determine how much oil the replacement compressor must contain before it is installed. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). REMOVAL - COMPRESSOR MOUNTING BRACKET - 2.4L ENGINE (1) Remove the compressor from the mounting bracket. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/COMPRESSOR - REMOVAL). (2) Remove the four screws that secure the compressor mounting bracket to the engine (Fig. 3). Fig. 3 Compressor Mounting Bracket - 2.4L Engine 1 - MOUNTING BRACKET 2 - SCREWS (4) 3 - ENGINE (3) Remove the compressor mounting bracket from the engine. INSTALLATION INSTALLATION - COMPRESSOR NOTE: If a replacement compressor is being installed, be certain to check the refrigerant oil level. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). Use only refrigerant oil of the type recommended for the compressor in the vehicle. (1) Position the compressor into the engine compartment. (2) On models with the 2.4L engine, loosely install the four screws that secure the compressor to the mounting bracket on the engine. Tighten the screws to 28 N·m (21 ft. lbs.). (3) On models with the 3.3L and 3.8L engines, loosely install the three screws and one nut that secure the compressor to the engine. Tighten each of the fasteners using the following sequence to 54 N·m (40 ft. lbs.). • The upper screw at the rear of the compressor. • The lower screw at the rear of the compressor. • The lower screw at the front of the compressor. • The upper nut at the front of the compressor. (4) On models with the 3.3L and 3.8L engines only, engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the compressor. (5) Reconnect the engine wire harness connector for the compressor clutch coil to the coil pigtail wire connector on the top of the compressor. (6) Reinstall the serpentine accessory drive belt onto the front of the engine. (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - 2.4L INSTALLATION) or (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - 3.3L/3.8L - INSTALLATION). (7) Lower the vehicle. (8) Remove the tape or plugs from the compressor discharge port and the discharge line fitting. (9) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. (10) Reconnect the discharge line fitting to the compressor discharge port. (11) Install and tighten the nut that secures the discharge line fitting to the compressor. Tighten the nut to 23 N·m (17 ft. lbs.). (12) Remove the tape or plugs from the compressor suction port and the suction line fitting. (13) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. (14) Reconnect the suction line fitting to the compressor suction port. (15) Install and tighten the nut that secures the suction line fitting to the compressor. Tighten the nut to 23 N·m (17 ft. lbs.). (16) Reconnect the battery negative cable. (17) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (18) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING - PLUMBING - FRONT RS 24 - 65 COMPRESSOR (Continued) FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). INSTALLATION - COMPRESSOR MOUNTING BRACKET - 2.4L ENGINE (1) Position the compressor mounting bracket onto the engine. (2) Install and tighten the four screws that secure the compressor mounting bracket to the engine. Tighten the screws to 54 N·m (40 ft. lbs.). (3) Reinstall the compressor onto the mounting bracket. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/COMPRESSOR - INSTALLATION). CONDENSER NOTE: Before removing the condenser, note the location of each of the radiator and condenser air seals. These air seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed. (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). (2) Remove the two large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember (Fig. 4). DESCRIPTION The condenser is integral to a cooling module which includes the radiator, the electric cooling fan, the fan shroud, air seals and an automatic transmission oil cooler. The cooling module is located in the air flow in the front of the engine compartment behind the radiator grille. The condenser cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The condenser may be removed from the cooling module for service without removing the cooling module from the vehicle. OPERATION The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins. When the refrigerant gas gives up its heat, it condenses. When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service. REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). Fig. 4 Radiator Sight Shield 1 2 3 4 5 - LARGE SCREWS (2) SMALL SCREWS (5) RADIATOR SIGHT SHIELD GRILLE INSERTS FRONT FASCIA (3) Remove the five small screws that secure the front fascia grille inserts to the radiator sight shield. (4) Remove the radiator sight shield from the radiator closure panel crossmember. (5) Remove the two screws that secure the hood latch unit to the front of the radiator closure panel crossmember and move the latch out of the way over the top of the crossmember. Mark the location of latch for reinstallation. (6) Disconnect the hoses from the transmission oil cooler fittings on the left side of the cooling module. (Refer to 7 - COOLING/TRANSMISSION/TRANS COOLER LINES - REMOVAL). (7) Remove the nut that secures the discharge line fitting to the condenser on the right side of the cooling module. 24 - 66 PLUMBING - FRONT RS CONDENSER (Continued) (8) Disconnect the discharge line fitting from the condenser inlet port. (9) Remove the seal from the discharge line fitting and discard. (10) Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. (11) Remove the nut that secures the liquid line fitting to the condenser on the right side of the cooling module. (12) Disconnect the liquid line fitting from the condenser outlet port. (13) Remove the seal from the liquid line fitting and discard. (14) Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port. (15) Remove the screw that secures the top of the mounting bracket on each side of the condenser to the cooling module (Fig. 5). (18) Remove the two screws that secure each mounting bracket to the sides of the condenser. (19) Remove the one screw that secures the left mounting bracket to the side of the transmission oil cooler. (20) Remove the left mounting bracket from the side of the condenser and transmission oil cooler. (21) Remove the condenser from the right mounting bracket and transmission oil cooler unit. INSTALLATION NOTE: If the condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. NOTE: Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations. These air seals are required in order for the air conditioning and engine cooling systems to perform as designed. (1) Position the condenser to the right mounting bracket and transmission oil cooler unit. (2) Position the left mounting bracket onto the side of the condenser and transmission oil cooler. (3) Install and tighten the one screw that secures the left mounting bracket to the side of the transmission oil cooler. Tighten the screw to 5 N·m (45 in. lbs.). (4) Install and tighten the two screws that secure each mounting bracket to the sides of the condenser. Tighten the screws to 5 N·m (45 in. lbs.). (5) Position the condenser, transmission oil cooler, and mounting brackets into the vehicle as a unit. Be certain that the locating pins that secure the mounting brackets are engaged in the lower mount rubber isolators on each side of the cooling module. NOTE: Verify that the condensor isolators are all installed and positioned correctly. Fig. 5 Condenser Mounting 1 - SCREW (2) 2 - LOWER MOUNT ISOLATOR (2) 3 - CONDENSER (16) Lift the condenser, transmission oil cooler, and mounting brackets as a unit far enough to disengage the locating pin that secures the mounting brackets in the lower mount rubber isolators on each side of the cooling module. (17) Remove the condenser, transmission oil cooler, and mounting brackets from the vehicle as a unit. (6) Install and tighten the two screws that secure the top of the mounting bracket on each side of the condenser to the cooling module. Tighten the screws to 5 N·m (45 in. lbs.). (7) Remove the tape or plugs from the condenser outlet port and the liquid line fitting. (8) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. (9) Reconnect the liquid line fitting to the condenser outlet port on the right side of the cooling module. PLUMBING - FRONT RS 24 - 67 CONDENSER (Continued) (10) Install and tighten the nut that secures the liquid line fitting to the condenser. Tighten the nut to 23 N·m (17 ft. lbs.). (11) Remove the tape or plugs from the condenser inlet port and the discharge line fitting. (12) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. (13) Reconnect the discharge line fitting to the condenser inlet port on the right side of the cooling module. (14) Install and tighten the nut that secures the discharge line fitting to the condenser. Tighten the nut to 23 N·m (17 ft. lbs.). (15) Reconnect the hoses to the transmission oil cooler fittings on the left side of the cooling module. (Refer to 7 - COOLING/TRANSMISSION/TRANS COOLER LINES - INSTALLATION). (16) Reposition the hood latch unit to the front of the radiator closure panel crossmember. (17) Install and tighten the two screws that secure the hood latch unit to the front of the radiator closure panel crossmember. Check and adjust the hood latch as needed. Tighten the screws to 14 N·m (123 in. lbs.). (18) Position the radiator sight shield onto the radiator closure panel crossmember. (19) Install and tighten the five small screws that secure the front fascia grille inserts to the radiator sight shield. Tighten the screws to 2 N·m (18 in. lbs.). (20) Install and tighten the two large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember. Tighten the screws to 6 N·m (53 in. lbs.). (21) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (22) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). DISCHARGE LINE REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). (2) Remove the two large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember (Fig. 6). Fig. 6 Radiator Sight Shield 1 2 3 4 5 - LARGE SCREWS (2) SMALL SCREWS (5) RADIATOR SIGHT SHIELD GRILLE INSERTS FRONT FASCIA (3) Remove the five small screws that secure the front fascia grille inserts to the radiator sight shield. (4) Remove the radiator sight shield from the radiator closure panel crossmember. (5) Remove the nut that secures the discharge line fitting to the condenser on the right side of the cooling module (Fig. 7). (6) Disconnect the discharge line fitting from the condenser inlet port. (7) Remove the seal from the discharge line fitting and discard. (8) Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. (9) Remove the nut that secures the discharge line fitting to the top of the compressor (Fig. 8). (10) Disconnect the discharge line fitting from the compressor discharge port. (11) Remove the seal from the discharge line fitting and discard. (12) Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port. (13) Remove the discharge line from the engine compartment. 24 - 68 PLUMBING - FRONT RS DISCHARGE LINE (Continued) Fig. 7 Condenser Connections 1 2 3 4 - CONDENSER DISCHARGE LINE FITTING LIQUID LINE FITTING NUT (5) Install and tighten the nut that secures the discharge line fitting to the compressor. Tighten the nut to 23 N·m (17 ft. lbs.). (6) Remove the tape or plugs from the condenser inlet port and the discharge line fitting. (7) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. (8) Reconnect the discharge line fitting to the condenser inlet port on the right side of the cooling module. (9) Install and tighten the nut that secures the discharge line fitting to the condenser. Tighten the nut to 23 N·m (17 ft. lbs.). (10) Position the radiator sight shield onto the radiator closure panel crossmember. (11) Install and tighten the five small screws that secure the front fascia grille inserts to the radiator sight shield. Tighten the screws to 2 N·m (18 in. lbs.). (12) Install and tighten the two large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember. Tighten the screws to 6 N·m (53 in. lbs.). (13) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (14) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). EVAPORATOR DESCRIPTION Fig. 8 Discharge Line 1 2 3 4 5 - DISCHARGE LINE NUT DISCHARGE LINE FITTING STUD DISCHARGE PORT INSTALLATION (1) Position the discharge line into the engine compartment. (2) Remove the tape or plugs from the compressor discharge port and the discharge line fitting. (3) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. (4) Reconnect the discharge line fitting to the compressor discharge port on the top of the compressor. The evaporator is located in the heater-A/C unit housing, behind the instrument panel. The evaporator is positioned in the heater-A/C housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator tubes. The heater-A/C unit housing must be removed from the vehicle to access the evaporator for service. The evaporator cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION Refrigerant enters the evaporator from the expansion valve as a low-temperature, low-pressure liquid/ vapor mixture. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, PLUMBING - FRONT RS 24 - 69 EVAPORATOR (Continued) 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 evaporator. REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). (1) Remove the HVAC unit housing from the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING REMOVAL). (2) Remove the heater core tubes from the heater core. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER CORE REMOVAL - HEATER CORE TUBES). (3) Remove and discard the foam seal from the HVAC housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening on the dash panel side of the unit. (4) Remove the expansion valve from the evaporator inlet and outlet tube fittings. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/EXPANSION VALVE - REMOVAL). (5) Disconnect the HVAC wire harness connector for the blower motor from the motor connector receptacle on the bottom of the outboard end of the evaporator housing. (6) Disengage the HVAC wire harness from the routing clips molded into the outside of the HVAC housing components. (7) Remove the three screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing (Fig. 9). (8) Pull the top of the distribution housing away from the evaporator housing far enough to disengage the two hook formations on the bottom of the distribution housing from the two receptacles on the evaporator housing (Fig. 10). (9) Remove the two screws that secure the upper intake air housing to the lower intake air housing. (10) Remove the three screws that secure the upper intake air housing to the top of the outboard end of the evaporator housing. Be certain not to miss the screw located just inside the inboard side of the fresh air intake opening. Fig. 9 HVAC Housing 1 2 3 4 5 - DISTRIBUTION HOUSING SCREWS (3) HVAC WIRING HARNESS ROUTING CLIP EVAPORATOR HOUSING Fig. 10 Distribution Housing Hooks 1 - RECEPTACLES ON EVAPORATOR HOUSING 2 - HOOKS ON DISTRIBUTION HOUSING (11) Remove the upper intake air housing from the top of the evaporator housing to expose the recirculation air door and the blower wheel housing (Fig. 11). (12) Remove the two screws that secure the upper half of the recirculation air door to the lower half of the door. (13) Remove the upper half of the recirculation air door from the lower half of the door (Fig. 12). (14) Remove the twelve screws around the perimeter of the evaporator housing that secure the upper housing half to the lower half. 24 - 70 PLUMBING - FRONT RS EVAPORATOR (Continued) Fig. 11 Upper Intake Air Housing 1 - EVAPORATOR HOUSING 2- UPPER INTAKE AIR HOUSING 3 - RECIRCULATION AIR DOOR 4 - BLOWER WHEEL Fig. 13 Evaporator Housing 1 2 3 4 - LOWER EVAPORATOR HOUSING UPPER EVAPORATOR HOUSING BLOWER WHEEL EVAPORATOR (16) Carefully lift the evaporator and its foam wrap out of the lower half of the evaporator housing as a unit. Be certain not to lose the clam shell type rubber seal that is fitted to the evaporator inlet and outlet tubes where they exit the evaporator housing. INSTALLATION NOTE: If the evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Fig. 12 Recirculation Air Door 1 - EVAPORATOR HOUSING 2 - UPPER RECIRCULATION AIR DOOR 3 - LOWER INTAKE AIR HOUSING (15) Carefully separate and remove the upper half of the evaporator housing from the lower half. Be certain not to lose the rubber grommet for the HVAC wire harness evaporator temperature sensor take out. This grommet is located on the inboard side of the flange around the expansion valve/evaporator tube opening on the dash panel side of the unit, where it is captured in a notched area between the upper and lower housing halves (Fig. 13). (1) Carefully lower the evaporator and its foam wrap into the lower half of the evaporator housing as a unit. Be certain that the clam shell type rubber seal is fitted to the evaporator inlet and outlet tubes where they exit the evaporator housing. (2) Position the upper half of the evaporator housing onto the lower half. Be certain that the rubber grommet and the HVAC wire harness take out for the evaporator temperature sensor are captured in the notched area between the upper and lower housing halves. (3) Install and tighten the twelve screws around the perimeter of the evaporator housing that secure the upper housing half to the lower half. Tighten the screws to 2 N·m (18 in. lbs.). (4) Position the upper half of the recirculation air door onto the lower half of the door. (5) Install and tighten the two screws that secure the upper half of the recirculation air door to the PLUMBING - FRONT RS 24 - 71 EVAPORATOR (Continued) lower half of the door. Tighten the screws to 2 N·m (18 in. lbs.). (6) Position the upper intake air housing onto the top of the evaporator housing over the recirculation air door and the blower wheel housing. Be certain that the upper pivot of the recirculation air door is captured in the pivot receptacle of the upper intake air housing. (7) Install and tighten the three screws that secure the upper intake air housing to the top of the outboard end of the evaporator housing. Be certain not to miss the screw located just inside the inboard side of the fresh air intake opening. Tighten the screws to 2 N·m (18 in. lbs.). (8) Install and tighten the two screws that secure the upper intake air housing to the lower intake air housing. Tighten the screws to 2 N·m (18 in. lbs.). (9) Engage the two hook formations on the bottom of the distribution housing in the two receptacles on the evaporator housing. (10) Roll the top of the distribution housing up into position against the evaporator housing. (11) Install and tighten the three screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing. Tighten the screws to 2 N·m (18 in. lbs.). (12) Engage the HVAC wire harness in the routing clips molded into the outside of the HVAC housing components. (13) Reconnect the HVAC wire harness connector for the blower motor with the motor connector receptacle on the bottom of the outboard end of the evaporator housing. (14) Reinstall the expansion valve onto the evaporator inlet and outlet tube fittings. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/EXPANSION VALVE - INSTALLATION). (15) Install a new foam seal onto the HVAC housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening on the dash panel side of the unit. (16) Reinstall the heater core tubes into the heater core. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER CORE INSTALLATION - HEATER CORE TUBES). (17) Reinstall the HVAC unit housing into the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - INSTALLATION). (18) Run the HVAC Control Actuator Calibration procedure(Refer to 24 - HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING)(Refer to 24 - HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING). EXPANSION VALVE DESCRIPTION The front “H” valve-type thermal expansion valve (TXV) is located at the dash panel between the liquid and suction lines, and the evaporator coil. The assembly consists of an H-valve body and a thermal sensor. High-pressure, low temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low-pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced. OPERATION A mechanical sensor in the expansion valve control head monitors the temperature and pressure of the refrigerant leaving the evaporator coil through the suction line, and adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the evaporator coil to meet the vehicle cooling requirements. Controlling the refrigerant flow through the evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the compressor. The thermo sensor measures refrigerant suction gas temperature which is monitored by the a/c control assembly. DIAGNOSIS AND TESTING - EXPANSION VALVE WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). NOTE: The expansion valve should only be tested following testing of the compressor. NOTE: Liquid CO is required to test the expansion valve. This material is available from most welding supply facilities. Liquid CO is also available from companies which service and sell fire extinguishers. When testing the expansion valve, the work area and the vehicle temperature must be 21° to 27° C (70° to 85° F). To test the expansion valve: (1) Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. 24 - 72 PLUMBING - FRONT RS EXPANSION VALVE (Continued) (2) Close all doors, windows and vents to the passenger compartment. (3) Set the heater-air conditioner controls so that the compressor is operating, the temperature control is in the highest temperature position, the mode door is directing the output to the floor outlets, and the blower is operating at the highest speed setting. (4) Start the engine and allow it to idle at 1000 rpm. After the engine has reached normal operating temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. (5) If the refrigerant charge is sufficient, the discharge (high pressure) gauge should read 965 to 1655 kPa (140 to 240 psi). The suction (low pressure) gauge should read 140 kPa to 207 kPa (20 psi to 30 psi). If OK, go to Step 6. If not OK, replace the faulty expansion valve. STANDARD PROCEDURE REFRIGERANT RECOVERY). (2) Disconnect and isolate the battery negative cable. (3) Remove the air cleaner housing from the right side of the engine compartment. (4) Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. (5) Disconnect the headlamp and dash wire harness connector for the A/C pressure transducer from the transducer on the front liquid line rear section (Fig. 14). WARNING: PROTECT THE SKIN AND EYES FROM EXPOSURE TO LIQUID CO. PERSONAL INJURY CAN RESULT. (6) If the suction (low pressure) gauge reads within the specified range, freeze the expansion valve control head for 30 seconds using liquid CO or another suitable super-cold material.Do not spray R-134a or R-12 refrigerant on the expansion valve control head for this test. The suction (low pressure) gauge reading should drop by 10 psi. If OK, go to Step 7 If not OK, replace the faulty expansion valve. (7) Allow the expansion valve control head to thaw. The suction (low pressure) gauge reading should stabilize at 140 kPa to 240 kPa (20 psi to 30 psi). If not OK, replace the faulty expansion valve. (8) When expansion valve testing is complete, test the overall air conditioner performance. (Refer to 24 HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST). Remove all test equipment before returning the vehicle to service. REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT - Fig. 14 Expansion Valve 1 2 3 4 5 6 - A/C PRESSURE TRANSDUCER - EVAPORATOR TEMPERATURE SENSOR - EXPANSION VALVE - SUCTION LINE - HIGH SIDE SERVICE PORT - FRONT LIQUID LINE REAR SECTION (6) Remove the screw that secures the front liquid line rear section fitting to the top of the filter-drier. (7) Disconnect the liquid line fitting from the filter-drier outlet port. (8) Remove the seal from the liquid line fitting and discard. (9) Install plugs in, or tape over the opened liquid line fitting and the filter-drier outlet port. (10) Remove the nut that secures the suction line and liquid line fittings to the stud on the expansion valve. (11) Disconnect the suction line and liquid line fittings from the expansion valve and move the lines out of the way. (12) Remove the seals from the suction line and liquid line fittings and discard. (13) Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. PLUMBING - FRONT RS 24 - 73 EXPANSION VALVE (Continued) (14) Remove the two screws that secure the expansion valve to the evaporator tube tapping plate. (15) Disconnect the HVAC wire harness connector for the evaporator temperature sensor from the sensor on the top of the expansion valve. (16) Remove the expansion valve from the evaporator inlet and outlet tube fittings. (17) Remove the seals from the evaporator inlet and outlet tube fittings and discard. (18) Install plugs in, or tape over the opened evaporator inlet and outlet tube fittings and both expansion valve ports. INSTALLATION (1) Remove the tape or plugs from the evaporator inlet and outlet tube fittings and both ports on the back of the expansion valve. (2) Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator inlet and outlet tube fittings. (3) Position the expansion valve onto the evaporator inlet and outlet tube fittings. (4) Install and tighten the two screws that secure the expansion valve to the evaporator tube tapping plate plate. Tighten the screws to 11 N·m (97 in. lbs.). (5) Reconnect the HVAC wire harness connector for the evaporator temperature sensor to the sensor connector receptacle on the top of the expansion valve. (6) Remove the tape or plugs from the front liquid line rear section and suction line fittings for the expansion valve and both ports on the front of the expansion valve. (7) Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the front liquid line rear section and suction line fittings for the expansion valve. (8) Reconnect the liquid line and suction line fittings to the expansion valve. (9) Install and tighten the nut that secures the suction line and liquid line fittings to the stud on the expansion valve. Tighten the nut to 23 N·m (17 ft. lbs.). (10) Remove the tape or plugs from the liquid line rear section fitting for the filter-drier and the filterdrier outlet port. (11) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. (12) Reconnect the liquid line fitting to the filterdrier outlet port on the top of the filter-drier. (13) Install and tighten the screw that secures the liquid line fitting to the filter-drier. Tighten the screw to 2 N·m (18 in. lbs.). (14) Reconnect the headlamp and dash wire harness connector for the A/C pressure transducer to the transducer on the front liquid line rear section. (15) Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. (16) Reinstall the air cleaner housing into the right side of the engine compartment. (17) Reconnect the battery negative cable. (18) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (19) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). HEATER CORE DESCRIPTION The heater core is located in the distribution housing of the heater-A/C unit, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. One end of the core is fitted with a molded plastic tank that includes integral heater core inlet and outlet ports. The removable heater core tubes are held in place these ports by a sealing plate secured with a screw to the heater core tank. This removable heater core tube arrangement allows the heater core to be serviced without removing the heater-A/C unit housing from the vehicle. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. OPERATION Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. 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 controlling how much of the air flowing through the heater-A/C unit housing is directed through the heater core. 24 - 74 PLUMBING - FRONT RS HEATER CORE (Continued) REMOVAL REMOVAL- HEATER CORE EXTENSION TUBES WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). 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 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. (1) Drain the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN). (2) Disconnect and isolate the battery negative cable. (3) Disconnect the heater hoses from the heater hose tubes. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER HOSE REMOVAL). (4) Remove the silencer from beneath the driver side end of the instrument panel. (Refer to 23 BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SILENCER - REMOVAL). (5) Remove the three screws that secure the heater core shield to the left end of the HVAC distribution housing (Fig. 15). (6) Pull the heater core shield rearward far enough to disengage the two location tabs that position the front of the shield to the receptacles in the two lower finger formations of the evaporator housing near the dash panel. (7) Remove the heater core shield from the distribution housing. (8) Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. (9) Remove the screw that secures the heater core tube sealing plate to the heater core supply and return ports (Fig. 16). Fig. 15 Heater Core Shield 1 2 3 4 5 - HEATER/ AIR CONDITIONER HOUSING HEATER CORE SHIELD DISTRIBUTION HOUSING SCREWS (3) LOCATION TABS (2) 1 2 3 4 5 6 - SEAL HEATER CORE TUBES SCREW HEATER CORE DISTRIBUTION HOUSING SEALING PLATE Fig. 16 Heater Core Tubes (10) Push both heater core tubes simultaneously toward the dash panel far enough to disengage their fittings from the heater core supply and return ports. (11) Install plugs in, or tape over the opened heater core tube fittings and both heater core ports. (12) Use absorbent toweling to mop up any engine coolant spills from the preceding operation. (13) Pull both heater core tubes simultaneously slightly away from the distribution housing and rear- PLUMBING - FRONT RS 24 - 75 HEATER CORE (Continued) ward far enough to disengage the engine compartment ends of the tubes from the dash panel seal. (14) Remove the heater core tubes and sealing plate as a unit from beneath the instrument panel. (15) Use absorbent toweling to clean up any engine coolant spills from the preceding operation. REMOVAL - HEATER CORE WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). 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 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. (1) Drain the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN). (2) Disconnect and isolate the battery negative cable. (3) Remove the silencer boot fasteners located around the base of the lower steering shaft from the dash panel so that it may be pushed aside. (4) Remove the brake lamp switch from its mounting bracket. (Refer to 8 - ELECTRICAL/LAMPS/ LIGHTING - EXTERIOR/BRAKE LAMP SWITCH REMOVAL). (5) Disconnect the power brake booster input rod (push rod) from the pin on the brake pedal arm. (Refer to 5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/POWER BRAKE BOOSTER - REMOVAL). (6) Remove the three screws that secure the heater core shield to the left end of the HVAC distribution housing (Fig. 17). (7) Pull the heater core shield rearward far enough to disengage the two location tabs that position the front of the shield to the receptacles in the two lower finger formations of the evaporator housing near the dash panel. Fig. 17 Heater Core Shield 1 2 3 4 5 - HEATER/ AIR CONDITIONER HOUSING HEATER CORE SHIELD DISTRIBUTION HOUSING SCREWS (3) LOCATION TABS (2) (8) Remove the heater core shield from the distribution housing. (9) Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to mop up any spills. (10) Remove the screw that secures the heater core tube sealing plate to the heater core supply and return ports (Fig. 18). Fig. 18 Heater Core 1 2 3 4 5 - SEALING PLATE SCREW SCREWS (2) HEATER CORE HEATER CORE TUBES 24 - 76 PLUMBING - FRONT RS HEATER CORE (Continued) (11) Push both heater core tubes simultaneously toward the dash panel far enough to disengage their fittings from the heater core supply and return ports. (12) Install plugs in, or tape over the opened heater core tube fittings and both heater core ports. (13) Use absorbent toweling to mop up any engine coolant spills from the preceding operation. (14) Remove the two screws that secure the heater core mounting plate to the distribution housing. (15) While pulling the accelerator pedal upward (Fig. 19) and pushing the brake pedal downward (Fig. 20) far enough for clearance, pull the heater core out of the distribution housing. (16) Use absorbent toweling to mop up any engine coolant spills from the preceding operation. Also, if the heater core was leaking, use absorbent toweling and reach into the heater core opening to mop up any residual engine coolant within the distribution housing. INSTALLATION INSTALLATION- HEATER CORE EXTENSION TUBES WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). Fig. 19 Accelerator Pedal 1 - SLIDE HEATER CORE PAST ACCELERATOR PEDAL Fig. 20 Brake Pedal 1 - SLIDE HEATER CORE PAST BRAKE PEDAL 2 - DEPRESS BRAKE PEDAL 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 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. (1) Remove the plugs or tape from both heater core tube fittings and both heater core ports. (2) Position the heater core tubes and sealing plate as a unit beneath the instrument panel. (3) Align the engine compartment ends of both heater core tubes with the openings in the dash panel seal and push them simultaneously forward through the seal far enough to engage the heater core ends of the tubes with the heater core supply and return ports. (4) Position both heater core tubes and the sealing plate simultaneously to the heater core supply and return ports. (5) The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed. RS PLUMBING - FRONT 24 - 77 HEATER CORE (Continued) (6) Install and tighten the screw that secures the heater core tube sealing plate to the heater core supply and return ports. Tighten the screw to 3 N·m (27 in. lbs.). (7) Position the heater core shield onto the distribution housing. Be certain that the two location tabs on the front of the shield are engaged in the receptacles in the two lower finger formations of the evaporator housing near the dash panel. (8) Install and tighten the three screws that secure the heater core shield to the left end of the HVAC distribution housing. Tighten the screws to 2 N·m (17 in. lbs.). (9) Reinstall the silencer under the driver side end of the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SILENCER - INSTALLATION). (10) Reconnect the heater hoses to the heater hose tubes. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER HOSE INSTALLATION). (11) Reconnect the battery negative cable. (12) Refill the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). INSTALLATION - HEATER CORE WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). 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 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. (1) While pushing the brake pedal downward and pulling the accelerator pedal upward far enough for clearance, slide the heater core into the distribution housing. (2) Install and tighten the two screws that secure the heater core mounting plate to the distribution housing. Tighten the screws to 2 N·m (17 in. lbs.). (3) Remove the plugs or tape from the heater core tube fittings and both heater core ports. (4) Position both heater core tubes and the sealing plate simultaneously to the heater core supply and return ports. (5) The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed. (6) Install and tighten the screw that secures the heater core tube sealing plate to the heater core supply and return ports. Tighten the screw to 3 N·m (27 in. lbs.). (7) Position the heater core shield onto the distribution housing. Be certain that the two location tabs on the front of the shield are engaged in the receptacles in the two lower finger formations of the evaporator housing near the dash panel. (8) Install and tighten the three screws that secure the heater core shield to the left end of the HVAC distribution housing. Tighten the screws to 2 N·m (17 in. lbs.). (9) Reconnect the power brake booster input rod (push rod) to the pin on the brake pedal arm(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/POWER BRAKE BOOSTER - INSTALLATION). (10) Reinstall the brake lamp switch into its mounting bracket(Refer to 8 - ELECTRICAL/LAMPS/ LIGHTING - EXTERIOR/BRAKE LAMP SWITCH INSTALLATION). (11) Reinstall the silencer boot around the base of the lower steering shaft on the dash panel. (12) Reconnect the battery negative cable. (13) Refill the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). (14) Operate system for two thermostat cycles to assure elimination of air in the system. 24 - 78 PLUMBING - FRONT RS HEATER HOSE REMOVAL There are several heater core plumbing configurations used on this model, depending upon the engine size and other optional equipment. One plumbing configuration is used for all 2.4L engines (Fig. 21), while the 3.3L and 3.8L engines have unique heater return plumbing on the engine for models with or without an optional engine oil cooler (Fig. 24) or (Fig. 25). There are also unique plumbing configurations at the heater core for models with or without the optional rear heater and air conditioner (Fig. 22) or (Fig. 23). All models use a combination of formed steel tubing and rubber hoses. In most cases, the rubber hose is secured to the steel tubing with a spring tension clamp. Fig. 22 Heater Plumbing - 3.3/3.8L Engine w/o Rear Heater 1 2 3 4 - ENGINE OUTLET NIPPLE HEATER CORE OUTLET HEATER CORE INLET HEATER RETURN TUBE & HOSE (TYPICAL) Fig. 21 Heater Plumbing - 2.4L Engine 1 2 3 4 5 6 7 8 - ENGINE OUTLET NIPPLE HEATER SUPPLY HEATER CORE OUTLET HEATER CORE INLET SCREW HEATER TUBE & HOSE UNIT HEATER RETURN ENGINE INLET NIPPLE WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). Fig. 23 Heater Plumbing - 3.3/3.8L Engine w/Rear Heater 1 2 3 4 5 6 - STUD HEATER CORE OUTLET HEATER CORE INLET TO ENGINE OUTLET NIPPLE TO UNDERBODY PLUMBING TO HEATER RETURN TUBE & HOSE (1) Drain the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN). (2) Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose to the tube or nipple toward the center of the hose to be removed. Release the clamp when it is off of the tube or nipple. PLUMBING - FRONT RS 24 - 79 HEATER HOSE (Continued) (3) After the clamp has been moved, grasp the end of the hose firmly and carefully twist the hose back and forth while pulling it away from the barbed end of the nipple. Repeat this procedure at the opposite end of the hose being removed. If this procedure is not successful in removing the hose from the nipple, carefully make a parallel cut through the hose where it is engaged on the nipple and peel the hose off of the nipple. This method of removal will require heater hose replacement. INSTALLATION Fig. 24 Heater Return - 3.3/3.8L Engine w/o Oil Cooler 1 2 3 4 - WATER PUMP RETURN NIPPLE HEATER RETURN TUBE & HOSE SCREW SCREW There are several heater core plumbing configurations used on this model, depending upon the engine size and other optional equipment. One plumbing configuration is used for all 2.4L engines, while the 3.3L and 3.8L engines have unique heater return plumbing on the engine for models with or without an optional engine oil cooler. There are also unique plumbing configurations at the heater core for models with or without the optional rear heater and air conditioner. All models use a combination of formed steel tubing and rubber hoses. In most cases, the rubber hose is secured to the steel tubing with a spring tension clamp. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). Fig. 25 Heater Return - 3.3/3.8L Engine w/Oil Cooler 1 2 3 4 5 6 - ENGINE INLET NIPPLE HEATER RETURN TUBE & HOSE SCREW SCREW OIL COOLER HEATER RETURN HOSE CAUTION: When removing the heater hose from the heater core or supply and return tube nipples, DO NOT apply excessive pressure. Excessive pressure may damage or deform the nipples and/or the heater core causing an engine coolant leak. (1) Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose toward the center of the hose being installed. Release the clamp when it is near the center of the hose. (2) Grasp one end of the heater hose being installed firmly and carefully twist the hose back and forth while pushing it over from the barbed end of the nipple. Repeat this procedure at the opposite end of the hose being installed. (3) Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose over the tube or nipple. Release the clamp when it is over the tube or nipple. (4) Refill the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). 24 - 80 PLUMBING - FRONT RS HEATER HOSES - DIESEL SUPPLEMENTAL HEATER BUX HEATER PIPES - DIESEL SUPPLEMENTAL HEATER BUX REMOVAL REMOVAL (1) Elevate vehicle on a lift taking note of the exhaust tube flexible section. (2) Drain cooling system(Refer to 7 - COOLING STANDARD PROCEDURE). (3) Lower heater unit from vehicle(Refer to 24 HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT - REMOVAL). NOTE: Complete removal of cabin heater from vehicle is not required, lowering unit allows easier access to coolant line clamps. (4) Remove clamps from both flexible coolant line ends. (5) Remove both lines from vehicle. NOTE: If either line is damaged it is recommended that both flexible lines be replaced. INSTALLATION (1) Install both flexible coolant lines to the heater unit and install clamps. (2) Install flexible coolant lines to the coolant pipes and install clamps. (3) Install heater unit into vehicle(Refer to 24 HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT - INSTALLATION). (4) Lower vehicle. (5) Refill cooling system(Refer to 7 - COOLING STANDARD PROCEDURE). (6) Verify operation of heater unit. CAUTION: Allow cooling system to cool completely before removing radiator cap or draining cooling system. Injury could result is system is opened while system coolant is hot and under pressure. NOTE: Steel heater lines from engine compartment to heater unit are part of an assembly that includes the air intake pipe. If the heater lines or air intake pipe require removal or replacement the entire assembly must be removed or replaced. (1) Open hood. (2) Drain the cooling system(Refer to 7 - COOLING - STANDARD PROCEDURE). (3) Remove clamps from both the EGR cooler and the lower heater port. Separate hoses from the mating plumbing port. (Fig. 26). (4) Remove retaining nut from heater line under hood bracket. (5) Elevate vehicle on a lift. NOTE: When supporting vehicle care should be taken not to damage the heater exhaust tube. (6) Remove clamps from heater lines to the rubber connection nearest the tubes. Separate the hoses from the tube assembly leaving the rubber hose attached to the supplemental heater. (7) Remove heater unit intake pipe from heater(Refer to 24 - HEATING & AIR CONDITIONING/ CABIN HEATER/INLET HOSE - REMOVAL) (Fig. 27). (8) Remove heater pipe assembly retaining screws and remove assembly from vehicle. PLUMBING - FRONT RS HEATER PIPES - DIESEL SUPPLEMENTAL HEATER - BUX (Continued) Fig. 26 CABIN HEATER PIPES 1 2 3 4 5 - HEATER CORE INTAKE PIPE - HEATER CORE RETURN PIPE - A/C LINES - A/C EXPANSION VALVE - A/C EXPANSION VALVE GROUND WIRE 6 - CABIN HEATER RETURN PIPE 7 - CABIN HEATER INTAKE PIPE 8 - CABIN HEATER PIPES RETAINING NUT 24 - 81 24 - 82 PLUMBING - FRONT RS HEATER PIPES - DIESEL SUPPLEMENTAL HEATER - BUX (Continued) LIQUID LINE REMOVAL The front air conditioner liquid line is serviced in two sections. The front section connects between the condenser and the filter/drier and includes the high side service port on the fitting for the filter/drier. The rear section connects between the filter/drier and the expansion valve and includes the fitting for the A/C pressure transducer. On models equipped with the optional rear air conditioner, the rear section of the front air conditioner liquid line also includes a liquid line hose and tube extension that connects the front liquid line to the liquid line for the rear air conditioner. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). Fig. 27 AIR INTAKE AND HEATER PIPE ASSEMBLY 1 2 3 4 5 - INTAKE TUBE AIR INTAKE INTAKE PIPE RETAINING SCREWS INTAKE HEATER LINE RETURN HEATER LINE INSTALLATION (1) With vehicle on a lift position the heater pipe assembly and install the retaining screws. (2) Install the heater unit intake pipe to the heater unit(Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/INLET HOSE - INSTALLATION). (3) Connect heater hoses to the heater unit and tighten the clamps. (4) Install heater unit intake pipe to heater unit (Refer to 24 - HEATING & AIR CONDITIONING/ CABIN HEATER/INLET HOSE - INSTALLATION). (5) Lower vehicle on lift. (6) Install retaining nut to heater line under hood bracket and tighten. (7) Connect heater lines to heater hoses at heater core and EGR port. Position spring clamps onto the installed hoses. (8) Refill cooling system(Refer to 7 - COOLING STANDARD PROCEDURE). (9) Close hood. FRONT SECTION (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT RECOVERY). (2) Disconnect and isolate the battery negative cable. (3) Remove the air cleaner housing from the right side of the engine compartment. (4) Remove the two large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember (Fig. 28). Fig. 28 Radiator Sight Shield 1 2 3 4 5 - LARGE SCREWS (2) SMALL SCREWS (5) RADIATOR SIGHT SHIELD GRILLE INSERTS FRONT FASCIA PLUMBING - FRONT RS 24 - 83 LIQUID LINE (Continued) (5) Remove the five small screws that secure the front fascia grille inserts to the radiator sight shield. (6) Remove the radiator sight shield from the radiator closure panel crossmember. (7) Remove the nut that secures the liquid line fitting to the condenser on the right side of the cooling module (Fig. 29). Fig. 30 Front Liquid Lines Fig. 29 Condenser Connections 1 2 3 4 - CONDENSER DISCHARGE LINE FITTING LIQUID LINE FITTING NUT (8) Disconnect the liquid line fitting from the condenser outlet port. (9) Remove the seal from the liquid line fitting and discard. (10) Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port. (11) Disengage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment (Fig. 30). (12) Remove the screw that secures the liquid line front section fitting to the top of the filter-drier. (13) Disconnect the liquid line fitting from the filter-drier inlet port. (14) Remove the seal from the liquid line fitting and discard. (15) Install plugs in, or tape over the opened liquid line fitting and the filter-drier inlet port. (16) Remove the front section of the front liquid line from the engine compartment. REAR SECTION (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). 1 - A/C GROUND STRAP 2 - NUT 3 - WELD STUD 4 - A/C PRESSURE TRANSDUCER 5 - WELD STUD (2) 6 - EXPANSION VALVE 7 - FRONT LIQUID LINE REAR SECTION 8 - LIQUID LINE EXTENSION (REAR A/C ONLY) 9 - NUT (2) 10 - FILTER-DRIER 11 - ROUTING CLIP 12 - FRONT LIQUID LINE FRONT SECTION (2) Disconnect and isolate the battery negative cable. (3) Remove the air cleaner housing from the right side of the engine compartment. (4) Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. (5) Remove the A/C pressure transducer from the fitting on the front liquid line rear section. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C PRESSURE TRANSDUCER - REMOVAL). (6) Remove the nut that secures the A/C ground strap to the weld stud on the top of the right front strut tower (Fig. 30). (7) Remove the A/C ground strap eyelet terminal connector from the weld stud. (8) Remove the screw that secures the liquid line rear section fitting to the top of the filter-drier. (9) Disconnect the liquid line fitting from the filter-drier outlet port. 24 - 84 PLUMBING - FRONT RS LIQUID LINE (Continued) (10) Remove the seal from the liquid line fitting and discard. (11) Install plugs in, or tape over the opened liquid line fitting and the filter-drier outlet port. (12) Remove the nut that secures the suction line and liquid line fittings to the expansion valve. (13) Disconnect the suction line and liquid line fittings from the expansion valve. (14) Remove the seals from the suction line and liquid line fittings and discard. (15) Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. (16) If the vehicle is equipped with the optional rear air conditioner, go to Step 17. If the vehicle does not have the optional rear air conditioner, go to Step 23. (17) Raise and support the vehicle. (18) Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heater and air conditioner (Fig. 31). Fig. 31 Underbody Connections 1 - SUCTION LINE EXTENSION 2 - LIQUID LINE EXTENSION 3 - TIE STRAP 4- HEATER LINE EXTENSIONS 5 - UNDERBODY LINES (19) Disconnect the front liquid line extension fitting from the underbody liquid line fitting for the rear air conditioner. (20) Remove the seal from the underbody liquid line fitting and discard. (21) Install plugs in, or tape over the opened liquid line fittings. (22) Lower the vehicle. (23) Remove the front liquid line rear section from the engine compartment. INSTALLATION The front air conditioner liquid line is serviced in two sections. The front section connects between the condenser and the filter/drier and includes the high side service port on the fitting for the filter/drier. The rear section connects between the filter/drier and the expansion valve and includes the fitting for the A/C pressure transducer. On models equipped with the optional rear air conditioner, the rear section of the front air conditioner liquid line also includes a liquid line hose and tube extension that connects the front liquid line to the liquid line for the rear air conditioner. FRONT SECTION (1) Position the front section of the front liquid line into the engine compartment. (2) Remove the tape or plugs from the liquid line front section fitting for the filter-drier and the filterdrier inlet port. (3) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. (4) Reconnect the liquid line fitting to the filterdrier inlet port on the top of the filter-drier. (5) Install and tighten the screw that secures the liquid line fitting to the filter-drier. Tighten the screw to 2 N·m (16 in. lbs.). (6) Engage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment. (7) Remove the tape or plugs from the condenser outlet port and the liquid line fitting. (8) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. (9) Reconnect the liquid line fitting to the condenser outlet port on the right side of the cooling module. (10) Install and tighten the nut that secures the liquid line fitting to the condenser. Tighten the nut to 23 N·m (17 ft. lbs.). (11) Position the radiator sight shield onto the radiator closure panel crossmember. (12) Install and tighten the five small screws that secure the front fascia grille inserts to the radiator sight shield. Tighten the screws to 2 N·m (16 in. lbs.). (13) Install and tighten the two large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember. Tighten the screws to 6 N·m (53 in. lbs.). (14) Reinstall the air cleaner housing into the right side of the engine compartment. (15) Reconnect the battery negative cable. (16) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - PLUMBING - FRONT RS 24 - 85 LIQUID LINE (Continued) FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (17) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). REAR SECTION (1) Position the rear section of the front liquid line into the engine compartment. (2) Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports. (3) Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings. (4) Reconnect the liquid line and suction line fittings to the expansion valve. (5) Install and tighten the nut that secures the suction line and liquid line fittings to the expansion valve. Tighten the nut to 23 N·m (17 ft. lbs.). (6) Remove the tape or plugs from the liquid line rear section fitting for the filter-drier and the filterdrier outlet port. (7) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. (8) Reconnect the liquid line fitting to the filterdrier outlet port on the top of the filter-drier. (9) Install and tighten the screw that secures the liquid line fitting to the filter-drier. Tighten the screw to 2 N·m (16 in. lbs.). (10) Reinstall the A/C ground strap eyelet terminal connector onto the weld stud on the top of the right front strut tower. (11) Install and tighten the nut that secures the A/C ground strap to the weld stud. Tighten the nut to 12 N·m (106 in. lbs.). (12) Reinstall the A/C pressure transducer onto the fitting on the front liquid line rear section. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C PRESSURE TRANSDUCER INSTALLATION). (13) Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. (14) Reinstall the air cleaner housing into the right side of the engine compartment. (15) Reconnect the battery negative cable. (16) If the vehicle is equipped with the optional rear air conditioner, go to Step 17. If the vehicle does not have the optional rear air conditioner, go to Step 23. (17) Raise and support the vehicle. (18) Remove the tape or plugs from the liquid line rear section extension fitting and the underbody liquid line fitting. (19) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody liquid line fitting. (20) Reconnect the liquid line rear section extension fitting to the underbody liquid line fitting. Tighten the fittings to 23 N·m (17 ft. lbs.). (21) Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heater and air conditioner. (22) Lower the vehicle. (23) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (24) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). RECEIVER/DRIER DESCRIPTION The filter-drier is mounted in a bracket secured to the right front strut tower in the engine compartment. The filter-drier is connected between the front and rear sections of the liquid line between the condenser outlet and the evaporator inlet. The filterdrier cannot be repaired. If the filter-drier is faulty or damaged, or if the refrigerant system has been contaminated or left open to the atmosphere for an indeterminable period, it must be replaced. OPERATION The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus refrigerant. Refrigerant enters the filter-drier as a high-pressure, low temperature liquid. REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). 24 - 86 PLUMBING - FRONT RS RECEIVER/DRIER (Continued) (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). (2) Remove the air cleaner housing from the right side of the engine compartment. (3) Remove the screw that secures the liquid line front section fitting to the top of the filter-drier (Fig. 32). (9) Remove the seal from the liquid line fitting and discard. (10) Install plugs in, or tape over the opened liquid line fitting and the filter-drier outlet port. (11) Remove the two nuts that secure the filterdrier mounting bracket to the weld studs on the side of the right front strut tower. (12) Remove the filter-drier and mounting bracket unit from the studs. INSTALLATION NOTE: If the filter-drier is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Fig. 32 Front Liquid Lines 1 - A/C GROUND STRAP 2 - NUT 3 - WELD STUD 4 - A/C PRESSURE TRANSDUCER 5 - WELD STUD (2) 6 - EXPANSION VALVE 7 - FRONT LIQUID LINE REAR SECTION 8 - LIQUID LINE EXTENSION (REAR A/C ONLY) 9 - NUT (2) 10 - FILTER-DRIER 11 - ROUTING CLIP 12 - FRONT LIQUID LINE FRONT SECTION (4) Disconnect the liquid line fitting from the filter-drier inlet port. (5) Remove the seal from the liquid line fitting and discard. (6) Install plugs in, or tape over the opened liquid line fitting and the filter-drier inlet port. (7) Remove the screw that secures the liquid line rear section fitting to the top of the filter-drier. (8) Disconnect the liquid line fitting from the filter-drier outlet port. (1) Position the filter-drier and mounting bracket unit onto the weld studs on the side of the right front strut tower. (2) Install and tighten the two nuts that secure the filter-drier mounting bracket to the studs. Tighten the nuts to 10 N·m (89 in. lbs.). (3) Remove the tape or plugs from the liquid line rear section fitting for the filter-drier and the filterdrier outlet port. (4) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. (5) Reconnect the liquid line fitting to the filterdrier outlet port on the top of the filter-drier. (6) Install and tighten the screw that secures the liquid line fitting to the filter-drier. Tighten the screw to 2 N·m (18 in. lbs.). (7) Remove the tape or plugs from the liquid line front section fitting for the filter-drier and the filterdrier inlet port. (8) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. (9) Reconnect the liquid line fitting to the filterdrier inlet port on the top of the filter-drier. (10) Install and tighten the screw that secures the liquid line fitting to the filter-drier. Tighten the screw to 2 N·m (18 in. lbs.). (11) Reinstall the air cleaner housing into the right side of the engine compartment. (12) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (13) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). RS REFRIGERANT 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. OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning 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 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 compressor identifying to service technicians that the air conditioning system is equipped with R-134a. DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). NOTE: The proper amount of R-134a refrigerant for the refrigerant system in this model is: • Single or Dual Zone (Front Unit Only) - 0.96 kilograms (2.13 pounds or 34 ounces) • Three Zone (Front and Rear Units) - 1.31 kilograms (2.88 pounds or 46 ounces) PLUMBING - FRONT 24 - 87 The procedure that follows should be used to determine whether the refrigerant system contains the proper refrigerant charge. Symptoms of an improper refrigerant charge (low) include: poor air conditioner performance, fog emitted from the air conditioner outlets, a hissing sound from the expansion valve/ evaporator area. There are two different methods with which the refrigerant charge level may be tested: • Using a DRBIIIt scan tool, a thermocouple and the Charge Determination Chart (Fig. 33). Refer to the appropriate diagnostic information. • Using a manifold gauge set, a thermocouple and the Charge Determination Chart (Fig. 33). A temperature probe is required to measure liquid line temperature. The clamp-on, Type K thermocouple temperature probe used in this procedure is available through the DaimlerChrysler Professional Service Equipment (PSE) program. This probe (PSE #66-324-0014 or #80PK-1A) is compatible with temperature-measuring instruments that accept Type K thermocouples, and have a miniature connector input. Other temperature probes are available through aftermarket sources; however, all references in this procedure will reflect the use of the probe made available through the PSE program. In order to use the temperature probe, a digital thermometer will also be required. If a digital thermometer is not available, an adapter is available through the PSE program that will convert any standard digital multimeter into a digital thermometer. This adapter is designed to accept any standard Type K thermocouple. If a digital multimeter is not available, this tool is also available through the PSE program. NOTE: When connecting the service equipment couplings to the refrigerant system service ports, be certain that the valve of each coupling is fully closed. This will reduce the amount of effort required to make the connection. (1) Remove the caps from the refrigerant system service ports and attach a manifold gauge set or a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 to the refrigerant system. (2) Attach a clamp-on thermocouple to the liquid line. The thermocouple must be placed as close to the A/C pressure transducer as possible to accurately observe liquid line temperature. (3) Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run at idle under the following conditions for five minutes. (a) Front windows are open. (b) Transaxle in Park. 24 - 88 PLUMBING - FRONT RS REFRIGERANT (Continued) (c) Front heater-A/C controls set to outside air, full cool, panel mode, blower high, and compressor engaged. (d) If the vehicle is so equipped, the rear heaterA/C controls must be set to full cool and blower high. (4) Raise the liquid line (discharge) pressure to about 1793 kPa (260 psi) by placing a piece of cardboard over part of the front side of the condenser. To place the cardboard properly, remove the upper radiator sight shield from the front fascia. Cover only enough of the condenser to raise and maintain the liquid line pressure at the specified level. (5) Observe the liquid line (discharge) pressure and liquid line temperature. Using the Charge Determination Chart (Fig. 33), determine whether the refrigerant system is operating within the Proper Charge Range. (a) If the refrigerant system is operating in the Undercharged area of the chart, add 0.057 kilogram (0.125 pound or 2 ounces) of refrigerant to the system. (b) If the refrigerant system is operating in the Overcharged area of the chart, reclaim 0.057 kilogram (0.125 pound or 2 ounces) of refrigerant from the system. (6) Recheck the system charge level following each refrigerant adjustment. Continue this process until the system readings are in the Proper Charge Range area on the Charge Determination Chart. DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). If the air conditioning system is not cooling properly, determine if the refrigerant system is fullycharged. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT - DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL). If the refrigerant system is low or empty; a leak at a refrigerant line, connector fitting, component, or component seal is likely. While an oily residue on or near refrigerant system lines, connector fittings, components, or component seals can indicate the general Fig. 33 Charge Determination Chart, Ambient Test Condition 85°F RS PLUMBING - FRONT 24 - 89 REFRIGERANT (Continued) location of a possible refrigerant leak, the exact leak location should be confirmed with an electronic leak detector prior to component repair or replacement. An electronic leak detector designed for R-134a refrigerant is recommended for locating and confirming refrigerant system leaks. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the results of the refrigerant system charge level test. and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). SYSTEM EMPTY (1) Evacuate the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (2) Connect and dispense 0.283 kilograms (0.625 pounds or 10 ounces) of R-134a refrigerant into the evacuated refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/ REFRIGERANT - STANDARD PROCEDURE REFRIGERANT SYSTEM CHARGE). (3) Proceed to the SYSTEM LOW procedures. The procedure that follows should be used to determine whether the refrigerant system contains the proper refrigerant charge. Symptoms of an improper refrigerant charge (low) include: poor air conditioner performance, fog emitted from the air conditioner outlets, a hissing sound from the expansion valve/ evaporator area. There are two different methods with which the refrigerant charge level may be tested: • Using a DRBIIIt scan tool, a thermocouple and the Charge Determination Chart (Fig. 34). Refer to the appropriate diagnostic information. • Using a manifold gauge set, a thermocouple and the Charge Determination Chart (Fig. 34). A temperature probe is required to measure liquid line temperature. The clamp-on, Type K thermocouple temperature probe used in this procedure is available through the DaimlerChrysler Professional Service Equipment (PSE) program. This probe (PSE #66-324-0014 or #80PK-1A) is compatible with temperature-measuring instruments that accept Type K thermocouples, and have a miniature connector input. Other temperature probes are available through aftermarket sources; however, all references in this procedure will reflect the use of the probe made available through the PSE program. In order to use the temperature probe, a digital thermometer will also be required. If a digital thermometer is not available, an adapter is available through the PSE program that will convert any standard digital multimeter into a digital thermometer. This adapter is designed to accept any standard Type K thermocouple. If a digital multimeter is not available, this tool is also available through the PSE program. SYSTEM LOW (1) Position the vehicle in a wind-free work area. This will aid in detecting small leaks. (2) Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run at idle under the following conditions for five minutes, then turning the engine off. (a) Front windows are open. (b) Rear air conditioner Off (if equipped). (c) Transaxle in Park. (d) Front heater-A/C controls set to outside air, panel mode, blower high, and compressor engaged. (3) Wait five to seven minutes and, with the engine not running, use a electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components. (4) To inspect an evaporator for leaks, insert the electronic leak detector probe into a floor outlet or the recirculation air intake. DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL 2.5L DIESEL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) NOTE: The proper amount of R-134a refrigerant for the refrigerant system in this model is: • Single or Dual Zone (Front Unit Only - 2.5L Diesel) – 0.91 kilograms (2.00 pounds or 32 ounces) • Single or Dual Zone (Front Unit Only) - 0.96 kilograms (2.13 pounds or 34 ounces) • Three Zone (Front and Rear Units) - 1.31 kilograms (2.88 pounds or 46 ounces) NOTE: When connecting the service equipment couplings to the refrigerant system service ports, be certain that the valve of each coupling is fully closed. This will reduce the amount of effort required to make the connection. (1) Remove the caps from the refrigerant system service ports and attach a manifold gauge set or a R-134a refrigerant recovery/recycling/charging sta- 24 - 90 PLUMBING - FRONT RS REFRIGERANT (Continued) tion that meets SAE Standard J2210 to the refrigerant system. (2) Attach a clamp-on thermocouple to the liquid line. The thermocouple must be placed as close to the A/C pressure transducer as possible to accurately observe liquid line temperature. (3) Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run at idle under the following conditions for five minutes. (a) Front windows are open. (b) Transaxle in Park. (c) Front heater-A/C controls set to outside air, full cool, panel mode, blower high, and compressor engaged. (d) If the vehicle is so equipped, the rear heaterA/C controls must be set to full cool and blower high. (4) Raise the liquid line (discharge) pressure to about 1793 kPa (260 psi) by placing a piece of cardboard over part of the front side of the condenser. To place the cardboard properly, remove the upper radiator sight shield from the front fascia. Cover only enough of the condenser to raise and maintain the liquid line pressure at the specified level. (5) Observe the liquid line (discharge) pressure and liquid line temperature. Using the Charge Determination Chart (Fig. 34), determine whether the refrigerant system is operating within the Proper Charge Range. (a) If the refrigerant system is operating in the Undercharged area of the chart, add 0.057 kilogram (0.125 pound or 2 ounces) of refrigerant to the system. (b) If the refrigerant system is operating in the Overcharged area of the chart, reclaim 0.057 kilogram (0.125 pound or 2 ounces) of refrigerant from the system. (6) Recheck the system charge level following each refrigerant adjustment. Continue this process until the system readings are in the Proper Charge Range area on the Charge Determination Chart (Fig. 34). STANDARD PROCEDURE STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT RECOVERY/RECYCLING STATION When servicing the air conditioning system, a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used (Fig. 35). Contact PSE or an automotive service equipment supplier for refrigerant recovery/recycling/ charging equipment. See the operating instructions Fig. 34 Charge Determination Chart, Ambient Test Condition 85°F PLUMBING - FRONT RS 24 - 91 REFRIGERANT (Continued) 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. Fig. 35 Refrigerant Recovery/Recycling Station Typical 1 - R-134 REFRIGERANT RECOVERY MACHINE supplied by the equipment manufacturer for proper care and use of this equipment. MANIFOLD GAUGE SET CONNECTIONS A manifold gauge set may be needed with some recovery/recycling/charging equipment (Fig. 36). The service hoses on the gauge set being used should have manual (turn wheel), or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into the atmosphere. • LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) attaches to the suction (low side) service port. This port is located on the suction line, near the compressor at the front of the engine compartment. • HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) attaches to the discharge (high side) service port. This port is located on the liquid line near the filter-drier at the rear of the engine compartment. • 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. STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). Fig. 36 Manifold Gauge Set - Typical 1 2 3 4 5 6 7 - HIGH PRESSURE GAUGE VALVE VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK STRIPE) HIGH PRESSURE HOSE (RED W/BLACK STRIPE) LOW PRESSURE HOSE (BLUE W/BLACK STRIPE) VALVE LOW PRESSURE GAUGE After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. For the proper amount of the refrigerant charge, refer to REFRIGERANT CHARGE CAPACITY . A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. REFRIGERANT CHARGE CAPACITY The R-134a refrigerant system charge capacity for this vehicle is: 24 - 92 PLUMBING - FRONT RS REFRIGERANT (Continued) • Single or Dual Zone (Front Unit Only - with 2.5L Turbo Diesel)0.91 kilograms (2.00 pounds or 32 ounces) • Single or Dual Zone (Front Unit Only) - 0.96 kilograms (2.13 pounds or 34 ounces) • Three Zone (Front and Rear Units) - 1.31 kilograms (2.88 pounds or 46 ounces) CHARGING PROCEDURE (1) Evacuate the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (2) A manifold gauge set and a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 should still be connected to the refrigerant system. (3) Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. (4) Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. (5) When the transfer of refrigerant has stopped, close both the suction and discharge valves. (6) If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heater-air conditioner controls so that the compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the compressor will not engage, test the compressor clutch control circuit and repair as required. (7) Open the suction valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH PRESSURE) VALVE AT THIS TIME. (8) Close the suction valve and test the system performance. (Refer to 24 - HEATING & AIR CONDITIONING - STANDARD PROCEDURE - A/C PERFORMANCE TEST). (9) Disconnect the charging station and manifold gauge set from the refrigerant system service ports. (10) Reinstall the caps onto the refrigerant system service ports. (11) Run the HVAC Control Cooldown test to verify proper operation(Refer to 24 - HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING). STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be charged. If moisture and air enters the system and becomes mixed with the refrigerant, the compressor head pressure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and damage the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to evacuate the refrigerant system. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. To evacuate the refrigerant system, use the following procedure: NOTE: When connecting the service equipment couplings to the refrigerant system service ports, be certain that the valve of each coupling is fully closed. This will reduce the amount of effort required to make the connection. (1) Remove the caps from the refrigerant system service ports and attach a manifold gauge set and a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 to the refrigerant system. (2) Open both the suction and discharge valves and start the charging station vacuum pump. (3) When the suction gauge has read 88 kPa (26 in. Hg.) vacuum or greater for 45 minutes, close both the suction and discharge valves and turn off the vacuum pump. If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be corrected. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT - STANDARD PROCEDURE REFRIGERANT SYSTEM LEAKS). (4) If the refrigerant system maintains the specified vacuum for thirty minutes, restart the vacuum pump, open both the suction and discharge valves, and evacuate the system for an additional ten minutes. (5) Close both the suction and discharge valves, and turn off the charging station vacuum pump. (6) The refrigerant system is now ready to be charged with R-134a refrigerant. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). PLUMBING - FRONT RS 24 - 93 REFRIGERANT (Continued) STANDARD PROCEDURE - REFRIGERANT RECOVERY WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system, whenever the refrigerant system must be opened for service. See the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. REFRIGERANT OIL 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 contains a different additive package. The 10S20H compressor used in this vehicle are designed to use an ND-8 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system. 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 compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much 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. STANDARD PROCEDURE - REFRIGERANT OIL LEVEL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). When an air conditioning system is assembled at the factory, all components except the compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor is dispersed throughout the refrigerant system. The receiver/drier, evaporator, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an receiver/ drier, evaporator or condenser is replaced. See the Refrigerant Oil Capacities chart for the proper amount of refrigerant oil to add. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of fresh new refrigerant oil that was drained out of the old compressor. REFRIGERANT OIL CAPACITIES Front A/C COMPONENT Front & Rear A/C ml fl oz ml fl oz Compressor 150 5.0 220 7.4 Filter-Drier 30 1.0 30 1.0 Condenser 30 1.0 30 1.0 Front Evaporator 60 2.0 60 2.0 Rear Evap. (including underbody lines) N/A N/A 60 2.0 Compressor Drain and measure the oil from the old compressor See text above. 24 - 94 PLUMBING - FRONT RS SUCTION LINE REMOVAL The front air conditioner suction line includes the low side service port on a section of tubing located near the compressor. On models equipped with the optional rear air conditioner, the front air conditioner suction line also includes a suction line hose and tube extension that connects the front suction line to the suction line for the rear air conditioner. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT RECOVERY). (2) Disconnect and isolate the battery negative cable. (3) Remove the air cleaner top cover and snorkel from the air cleaner housing located on the right side of the engine compartment. (4) Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. (5) Remove the nut that secures the suction line fitting to the top of the compressor. (6) Disconnect the suction line fitting from the compressor suction port. (7) Remove the seal from the suction line fitting and discard. (8) Install plugs in, or tape over the opened suction line fitting and the compressor suction port. (9) Disengage the retainer that secures the suction line routing clip to the filter-drier mounting bracket on the side of the right front strut tower in the engine compartment (Fig. 37). (10) Remove the nut that secures the suction line and liquid line fittings to the expansion valve. (11) Disconnect the suction line and liquid line fittings from the expansion valve. (12) Remove the seals from the suction line and liquid line fittings and discard. (13) Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. (14) If the vehicle is equipped with the optional rear air conditioner, go to Step 15. If the vehicle does not have the optional rear air conditioner, go to Step 21. Fig. 37 Suction Line 1 2 3 4 5 - EXPANSION VALVE SUCTION LINE EXTENSION (REAR A/C ONLY) NUT ROUTING CLIP SUCTION LINE (15) Raise and support the vehicle. (16) Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heater and air conditioner (Fig. 38). Fig. 38 Underbody Connections 1 - SUCTION LINE EXTENSION 2 - LIQUID LINE EXTENSION 3 - TIE STRAP 4- HEATER LINE EXTENSIONS 5 - UNDERBODY LINES PLUMBING - FRONT RS 24 - 95 SUCTION LINE (Continued) (17) Disconnect the suction line extension fitting from the underbody suction line fitting for the rear air conditioner. (18) Remove the seal from the underbody suction line fitting and discard. (19) Install plugs in, or tape over the opened suction line fittings. (20) Lower the vehicle. (21) Remove the suction line from the engine compartment. INSTALLATION The front air conditioner suction line includes the low side service port on a section of tubing located near the compressor. On models equipped with the optional rear air conditioner, the front air conditioner suction line also includes a suction line hose and tube extension that connects the front suction line to the suction line for the rear air conditioner. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (1) Position the suction line into the engine compartment. (2) Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports. (3) Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings. (4) Reconnect the liquid line and suction line fittings to the expansion valve. (5) Install and tighten the nut that secures the suction line and liquid line fittings to the expansion valve. Tighten the nut to 23 N·m (17 ft. lbs.). (6) Engage the retainer that secures the suction line routing clip to the filter-drier mounting bracket on the side of the right front strut tower in the engine compartment. (7) Remove the tape or plugs from the compressor suction port and the suction line fitting. (8) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. (9) Reconnect the suction line fitting to the compressor suction port. (10) Install and tighten the nut that secures the suction line fitting to the compressor. Tighten the nut to 23 N·m (17 ft. lbs.). (11) Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. (12) Reinstall the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment. (13) Reconnect the battery negative cable. (14) If the vehicle is equipped with the optional rear air conditioner, go to Step 15. If the vehicle does not have the optional rear air conditioner, go to Step 21. (15) Raise and support the vehicle. (16) Remove the tape or plugs from the suction line extension fitting and the underbody suction line fitting. (17) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line fitting. (18) Reconnect the suction line extension fitting to the underbody suction line fitting. Tighten the fittings to 23 N·m (17 ft. lbs.). (19) Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heater and air conditioner. (20) Lower the vehicle. (21) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (22) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). SERVICE PORTS REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (1) Remove the protective cap from the A/C service port (Fig. 39). (2) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). (3) Using a standard Schrader-type valve core tool, remove the valve core from the A/C service port. (4) Install a plug in or tape over the opened A/C service port. 24 - 96 PLUMBING - FRONT RS SERVICE PORTS (Continued) (1) Lubricate the A/C service port valve core with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the compressor in the vehicle. (2) Remove the tape or plug from the A/C service port. (3) Using a standard Schrader-type valve core tool, install and tighten the replacement valve core into the A/C service port. 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. Fig. 39 A/C Service Port - Typical 1 2 3 4 5 6 - RIGHT FRONT STRUT TOWER - CONNECTOR - A/C PRESSURE TRANSDUCER - RIGHT WIPER MODULE DRAIN TUBE - HIGH SIDE SERVICE PORT - LIQUID LINE INSTALLATION WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (4) Evacuate the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (5) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). (6) Reinstall the protective cap onto the A/C service port. PLUMBING - REAR RS 24 - 97 PLUMBING - REAR TABLE OF CONTENTS page page EVAPORATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 97 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 REMOVAL REMOVAL - REAR EVAPORATOR . . . . . . . . . 97 REMOVAL - EVAPORATOR LINE EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . 98 INSTALLATION INSTALLATION - REAR EVAPORATOR . . . . . 99 INSTALLATION - EVAPORATOR LINE EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . 99 EXPANSION VALVE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 99 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 100 DIAGNOSIS AND TESTING - EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101 HEATER CORE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 101 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 101 STANDARD PROCEDURE - HEATER CORE FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . HEATER HOSE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . SUCTION LINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . UNDERBODY LINES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - REAR HEATER LINES . . . . . . REMOVAL - REAR AIR CONDITIONING LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION - REAR HEATER LINES . . . INSTALLATION - REAR AIR CONDITIONING LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . EVAPORATOR REMOVAL DESCRIPTION REMOVAL - REAR EVAPORATOR The rear evaporator is located in the rear heaterA/C unit housing, behind the right rear wheel house. The evaporator is positioned in the rear heater-A/C housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator tubes. The rear heater-A/C unit housing must be removed from the vehicle to access the evaporator for service. The evaporator cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. OPERATION Refrigerant enters the rear evaporator from the rear expansion valve as a low-temperature, low-pressure liquid. As air flows over the fins of the 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 evaporator. . 101 . 102 . 103 . 103 . 103 . 104 . 105 . 106 . 106 . 107 . 107 . 108 . 108 WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). (1) Remove the rear heater-A/C unit housing from the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR HEATERA/C HOUSING - REMOVAL). (2) Remove the rear evaporator line extension from the expansion valve. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/EVAPORATOR - REMOVAL - EVAPORATOR LINE EXTENSION). (3) Remove the rear expansion valve from the rear evaporator. (Refer to 24 - HEATING & AIR CONDI- 24 - 98 PLUMBING - REAR RS EVAPORATOR (Continued) TIONING/PLUMBING - REAR/EXPANSION VALVE - REMOVAL). (4) Remove the rubber grommet that seals the evaporator inlet and outlet tubes to the rear heaterA/C housing near the expansion valve. (5) Remove the three screws that secure the upper half of the rear heater-A/C housing to the lower half (Fig. 1). within the base of the rear heater-A/C unit housing (Fig. 2). Fig. 2 Evaporator Line Extension Plate 1 - REAR HEATER-A/C HOUSING BASE 2 - PLATE 3 - EVAPORATOR LINE EXTENSION Fig. 1 Rear Evaporator 1 - UPPER REAR HEATER-A/C HOUSING 2 - EVAPORATOR 3 - LOWER REAR HEATER-A/C HOUSING (3) Remove the capture plate from the rear heaterA/C unit housing base. (4) Carefully peel back the expansion valve foam insulator wrap far enough to access the evaporator line extension sealing plate on the bottom of the expansion valve (Fig. 3). (6) Remove the three small metal spring clips that secure the upper half of the rear heater-A/C housing to the lower half. (7) Carefully separate and remove the upper half of the rear heater-A/C housing from the lower half. (8) Remove the evaporator from the lower half of the rear heater-A/C housing. REMOVAL - EVAPORATOR LINE EXTENSION WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). (1) Remove the rear heater-A/C unit housing from the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR HEATERA/C HOUSING - REMOVAL). (2) Remove the screw that secures the plate that captures and seals the evaporator line extension Fig. 3 Evaporator Line Extension 1 2 3 4 5 6 - UPPER REAR HEATER-A/C HOUSING LOWER REAR HEATER-A/C HOUSING EXPANSION VALVE BRACKET EVAPORATOR LINE EXTENSION EXPANSION VALVE STUD INSULATOR WRAP PLUMBING - REAR RS 24 - 99 EVAPORATOR (Continued) (5) Remove the two screws that secure the expansion valve bracket to the lower rear heater-A/C unit housing. (6) Remove the nut that secures the expansion valve bracket to the expansion valve stud. (7) Remove the expansion valve bracket from the expansion valve stud. (8) Remove the nut that secures the evaporator line extension seal plate to the expansion valve stud. (9) Remove the evaporator line extension seal plate from the expansion valve stud. (10) Remove the evaporator line extension from the expansion valve and the rear heater-A/C housing base. (11) Remove the seals from the evaporator line extension fittings and discard. (12) Install plugs in, or tape over the opened evaporator line extension fittings and both expansion valve ports. INSTALLATION INSTALLATION - REAR EVAPORATOR NOTE: If the evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. (1) Carefully lower the evaporator and its foam wrap into the lower half of the rear heater-A/C housing. (2) Position the upper half of the rear heater-A/C housing onto the lower half. (3) Install the three small metal spring clips that secure the upper half of the rear heater-A/C housing to the lower half. (4) Install and tighten the three screws that secure the upper half of the rear heater-A/C housing to the lower half. Tighten the screws to 2 N·m (18 in. lbs.). (5) Install the rubber grommet that seals the evaporator inlet and outlet tubes to the rear heater-A/C housing near the expansion valve. (6) Reinstall the rear expansion valve onto the rear evaporator. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/EXPANSION VALVE - INSTALLATION). (7) Reinstall the rear evaporator extension line onto the expansion valve. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/EVAPORATOR - INSTALLATION - EVAPORATOR EXTENSION LINE). (8) Reinstall the rear heater-A/C unit housing into the vehicle. (Refer to 24 - HEATING & AIR CONDI- TIONING/DISTRIBUTION - REAR/REAR HEATERA/C HOUSING - INSTALLATION). INSTALLATION - EVAPORATOR LINE EXTENSION (1) Remove the tape or plugs from the evaporator line extension fittings and both expansion valve ports. (2) Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator line extension fittings. (3) Position the evaporator line extension to the expansion valve and the rear heater-A/C housing base. (4) Position the evaporator line extension seal plate over the expansion valve stud. (5) Install and tighten the nut that secures the evaporator line extension seal plate to the expansion valve stud. Tighten the nut to 23 N·m (17 ft. lbs.). (6) Position the expansion valve bracket over the expansion valve stud. (7) Install and tighten the two screws that secure the expansion valve bracket to the lower rear heaterA/C unit housing. Tighten the screws to 2 N·m (18 in. lbs.). (8) Install and tighten the nut that secures the expansion valve bracket to the expansion valve stud. Tighten the nut to 23 N·m (17 ft. lbs.). (9) Carefully restore the expansion valve foam insulator wrap back around the expansion valve. (10) Position the plate that captures and seals the evaporator line extension onto the rear heater-A/C unit housing base. (11) Install and tighten the screw that secures the capture plate to the base of the rear heater-A/C unit housing. Tighten the screw to 2 N·m (18 in. lbs.). (12) Reinstall the rear heater-A/C unit housing into the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR HEATER-A/C HOUSING - INSTALLATION). EXPANSION VALVE DESCRIPTION The rear “H” valve-type thermal expansion valve (TXV) is located at the rear of the rear heater-A/C unit housing between the evaporator line extension and the evaporator coil. High-pressure, low temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low-pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced. 24 - 100 PLUMBING - REAR RS EXPANSION VALVE (Continued) OPERATION A mechanical sensor in the expansion valve control head monitors the temperature and pressure of the refrigerant leaving the evaporator coil through the suction line, and adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the evaporator coil to meet the vehicle cooling requirements. Controlling the refrigerant flow through the evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the compressor. DIAGNOSIS AND TESTING - EXPANSION VALVE WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). NOTE: The expansion valve should only be tested following testing of the compressor. NOTE: Liquid CO is required to test the expansion valve. This material is available from most welding supply facilities. Liquid CO is also available from companies which service and sell fire extinguishers. When testing the expansion valve, the work area and the vehicle temperature must be 21° to 27° C (70° to 85° F). To test the expansion valve: (1) Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. (2) Close all doors, windows and vents to the passenger compartment. (3) Set the heater-air conditioner controls so that the compressor is operating, the temperature control is in the highest temperature position, the mode door is directing the output to the floor outlets, and the blower is operating at the highest speed setting. (4) Start the engine and allow it to idle at 1000 rpm. After the engine has reached normal operating temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. (5) If the refrigerant charge is sufficient, the discharge (high pressure) gauge should read 965 to 1655 kPa (140 to 240 psi). The suction (low pressure) gauge should read 140 kPa to 207 kPa (20 psi to 30 psi). If OK, go to Step 6. If not OK, replace the faulty expansion valve. WARNING: PROTECT THE SKIN AND EYES FROM EXPOSURE TO LIQUID CO. PERSONAL INJURY CAN RESULT. (6) If the suction (low pressure) gauge reads within the specified range, freeze the expansion valve control head for 30 seconds using liquid CO or another suitable super-cold material.Do not spray R-134a or R-12 refrigerant on the expansion valve control head for this test. The suction (low pressure) gauge reading should drop by 10 psi. If OK, go to Step 7 If not OK, replace the faulty expansion valve. (7) Allow the expansion valve control head to thaw. The suction (low pressure) gauge reading should stabilize at 140 kPa to 240 kPa (20 psi to 30 psi). If not OK, replace the faulty expansion valve. (8) When expansion valve testing is complete, test the overall air conditioner performance. (Refer to 24 HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST). Remove all test equipment before returning the vehicle to service. REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING), (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING), and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - HEATER PLUMBING). (1) Remove the rear heater-A/C unit housing from the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR HEATERA/C HOUSING - REMOVAL). (2) Carefully remove the foam insulator wrap from the rear expansion valve. (3) Remove the rear evaporator line extension from the expansion valve. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/EVAPORATOR - REMOVAL - EVAPORATOR LINE EXTENSION). (4) Remove the two screws that secure the expansion valve to the evaporator tube sealing plate. (5) Remove the expansion valve from the evaporator tubes. (6) Remove the seals from the evaporator tube fittings and discard. (7) Install plugs in, or tape over the opened evaporator tube fittings and both expansion valve ports. RS PLUMBING - REAR 24 - 101 EXPANSION VALVE (Continued) INSTALLATION (1) Remove the tape or plugs from the evaporator tube fittings and both expansion valve ports. (2) Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator tube fittings. (3) Position the expansion valve onto the evaporator tubes. (4) Install and tighten the two screws that secure the expansion valve to the evaporator tube sealing plate. Tighten the screws to 11 N·m (97 in. lbs.). (5) Reinstall the rear evaporator line extension onto the expansion valve. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/EVAPORATOR - INSTALLATION - EVAPORATOR LINE EXTENSION). (6) Install the foam insulator wrap over the rear expansion valve. (7) Reinstall the rear heater-A/C unit housing into the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/REAR HEATERA/C HOUSING - INSTALLATION). (8) Run the HVAC Cooldown Test to verify proper operation. HEATER CORE DESCRIPTION The rear heater core is located near the front of the rear heater-A/C unit housing, behind the right rear wheel house. It is a heat exchanger made of rows of tubes and fins. One end of the core is fitted with a molded plastic tank that includes integral heater core inlet and outlet nipples. The heater core can be serviced without removing the rear heater-A/C unit housing from the vehicle. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. fore, when the cooling system is drained and refilled, gravity will not refill the heater core with coolant to the proper level. This may result in two problems: 1. Insufficient coolant level in the engine cooling system, which may result in engine overheating. 2. Air entrapped within the rear heater core, which may result in insufficient rear heater performance. There are two methods that may be employed to prevent these problems: 1. Pre-filling of the rear heater core. 2. Thermal cycling of the engine cooling system. Following are descriptions of both prevention methods, as well as a method to verify rear heater performance. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). PRE-FILLING If the rear heater core or the rear heater-A/C housing have been removed from the vehicle for service, the rear heater core may be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings. (1) The heater core should be installed in the rear heater-A/C unit housing, and the rear heater-A/C unit housing should be installed in the vehicle. (2) Take the proper precautions to protect the carpeting below the rear heater core from spilled engine coolant and have absorbent toweling readily available to mop up any spills. (3) Insert the small end of an appropriate funnel into the upper hose fitting of the heater core (Fig. 4). OPERATION Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. 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 controlling how much of the air flowing through the rear heater-A/C unit housing is directed through the heater core. STANDARD PROCEDURE - HEATER CORE FILLING In its final installed position, the rear heater core is positioned higher than the radiator fill cap. There- Fig. 4 Pre-Filling Heater Core - Typical 1 - REAR HEATER CORE 24 - 102 PLUMBING - REAR RS HEATER CORE (Continued) (4) Carefully pour the proper pre-mixed engine coolant solution into the rear heater core through a funnel until coolant begins to appear at the lower hose fitting of the heater core. (5) Use absorbent toweling to clean up any engine coolant spills from the preceding operation. (6) Reconnect the heater hoses to the rear heater core. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - INSTALLATION). (7) Refill the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). THERMAL CYCLING If the rear heater core was emptied and was not pre-filled, it will be necessary to thermal cycle the vehicle at least two times to ensure that the rear heater core is properly filled. (1) Refill the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). (2) Start the engine and allow it to operate until the thermostat opens. (3) Turn the engine off and allow it to cool. (4) With the engine cold and not running, check and top off the engine coolant level as necessary. (Refer to 7 - COOLING - STANDARD PROCEDURE - COOLANT LEVEL CHECK) and (Refer to 7 COOLING - STANDARD PROCEDURE - COOLANT - ADDING). (5) Start the engine and allow it to operate until the thermostat opens again. (6) Turn the engine off and allow it to cool down again. (7) With the engine cold and not running, check and top off the engine coolant level as necessary. (Refer to 7 - COOLING - STANDARD PROCEDURE - COOLANT LEVEL CHECK) and (Refer to 7 COOLING - STANDARD PROCEDURE - COOLANT - ADDING). (8) Check the performance of the rear heater. Refer to REAR HEATER PERFORMANCE CHECK . REAR HEATER PERFORMANCE CHECK Successful completion of the rear heater performance check will confirm that the rear heater core is properly filled with engine coolant. If the check is not successful, either there is still air trapped in the rear heater core or the rear heater plumbing is restricted. This check should be performed with the vehicle in a shop where the ambient temperature is about 21° C (70° F). (1) Start the engine and allow it to idle until it warms up to normal operating temperature. (2) Adjust the heater-A/C controls so that the front heater is turned Off, the rear heater is set for full Heat, and the rear blower motor is at its highest speed setting. (3) Use an accurate test thermometer to measure the temperature of the air being discharged from the rear heater outlet located at the base of the right C-pillar. (4) Proper discharge air temperature readings should be from 57° to 63° C (135° to 145° F). REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). (1) Drain the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN). (2) Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - REMOVAL). (3) Remove the rear heater distribution duct from the right quarter inner panel. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/REAR HEATER DISTRIBUTION DUCT REMOVAL). (4) Remove the screw that secures the back of the rear heater-A/C unit housing to the right D-pillar. (5) Remove the screw that secures the front of the rear heater-A/C unit housing to the right quarter inner panel. (6) Take the proper precautions to protect the carpeting below the rear heater core from spilled engine coolant and have absorbent toweling readily available to mop up any spills. (7) Disconnect the heater hoses at the rear heater core. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - REMOVAL). (8) Install plugs in, or tape over the opened heater core fittings and both heater hoses (Fig. 5). (9) Use absorbent toweling to clean up any engine coolant spills from the preceding operation. (10) Release the four latch tabs that secure the heater core in the rear heater-A/C unit housing. (11) Carefully pull the heater core straight out of the rear heater-A/C unit housing. (12) Use absorbent toweling to clean up any engine coolant spills from the preceding operation. PLUMBING - REAR RS 24 - 103 HEATER CORE (Continued) ING & AIR CONDITIONING/DISTRIBUTION REAR/REAR HEATER DISTRIBUTION DUCT INSTALLATION). (8) Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. (Refer to 23 - BODY/INTERIOR/QUARTER TRIM PANEL - INSTALLATION). (9) Drain the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). HEATER HOSE REMOVAL Fig. 5 Heater Core 1 2 3 4 5 6 - REAR HEATER-A/C HOUSING OUTLET REAR HEATER-A/C UNIT HOUSING LATCH (4) HEATER CORE RIGHT REAR WHEEL HOUSE HEATER HOSES INSTALLATION NOTE: If the rear heater core or the rear heater-A/C housing have been removed from the vehicle for service, the rear heater core may be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - REAR/HEATER CORE - STANDARD PROCEDURE - HEATER CORE FILLING). (1) Carefully slide the heater core into the rear heater-A/C unit housing. (2) Using hand pressure, press firmly and evenly on the heater core end plate until the four latch tabs that secure the heater core in the rear heater-A/C unit housing are fully engaged (Fig. 5). (3) Remove the plugs or tape from the heater core fittings and both heater hoses. (4) Reconnect the heater hoses to the rear heater core. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - INSTALLATION). (5) Install and tighten the screw that secures the front of the rear heater-A/C unit housing to the right quarter inner panel. Tighten the screw to 11 N·m (97 in. lbs.). (6) Install and tighten the screw that secures the back of the rear heater-A/C unit housing to the right D-pillar. Tighten the screw to 11 N·m (97 in. lbs.). (7) Reinstall the rear heater distribution duct onto the right quarter inner panel. (Refer to 24 - HEAT- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT - WARNING - HEATER PLUMBING). (1) Partially drain engine cooling system. Refer to Group 7, Engine Cooling. (2) Loosen clamp at the front end of the hose located at the right, outboard side of the underbody, rearward of the front crossmember. (Fig. 9) (3) Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. CAUTION: When removing hoses from outlet nipples, do not use excessive force. Outlet nipples may become damaged and leak engine coolant. (4) Compress insert in rear heater hose quick connection and pull downward on hose. (Fig. 11) (5) Remove (3) straps securing underbody lines. (Fig. 8) (6) Separate and remove rear heater lines from vehicle. INSTALLATION There are several heater core plumbing configurations used on this model, depending upon the engine size and other optional equipment. One plumbing configuration is used for all 2.4L engines, while the 3.3L and 3.8L engines have unique heater return plumbing on the engine for models with or without an optional engine oil cooler. There are also unique plumbing configurations at the heater core for models with or without the optional rear heater and air conditioner. All models use a combination of formed steel tubing and rubber hoses. In most cases, the rubber hose is secured to the steel tubing with a spring tension clamp. 24 - 104 PLUMBING - REAR RS HEATER HOSE (Continued) WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING FRONT - WARNING - HEATER PLUMBING). (1) Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose toward the center of the hose being installed. Release the clamp when it is near the center of the hose. (2) Grasp one end of the heater hose being installed firmly and carefully twist the hose back and forth while pushing it over from the barbed end of the nipple. Repeat this procedure at the opposite end of the hose being installed. (3) Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose over the tube or nipple. Release the clamp when it is over the tube or nipple. (4) Refill the engine cooling system. (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). (4) Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. (5) Remove the nut that secures the suction line fitting to the top of the compressor. (6) Disconnect the suction line fitting from the compressor suction port. (7) Remove the seal from the suction line fitting and discard. (8) Install plugs in, or tape over the opened suction line fitting and the compressor suction port. (9) Disengage the retainer that secures the suction line routing clip to the filter-drier mounting bracket on the side of the right front strut tower in the engine compartment (Fig. 6). SUCTION LINE REMOVAL The front air conditioner suction line includes the low side service port on a section of tubing located near the compressor. On models equipped with the optional rear air conditioner, the front air conditioner suction line also includes a suction line hose and tube extension that connects the front suction line to the suction line for the rear air conditioner. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY). (2) Disconnect and isolate the battery negative cable. (3) Remove the air cleaner top cover and snorkel from the air cleaner housing located on the right side of the engine compartment. Fig. 6 Suction Line 1 2 3 4 5 - EXPANSION VALVE SUCTION LINE EXTENSION (REAR A/C ONLY) NUT ROUTING CLIP SUCTION LINE (10) Remove the nut that secures the suction line and liquid line fittings to the expansion valve. (11) Disconnect the suction line and liquid line fittings from the expansion valve. (12) Remove the seals from the suction line and liquid line fittings and discard. (13) Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. PLUMBING - REAR RS 24 - 105 SUCTION LINE (Continued) (14) If the vehicle is equipped with the optional rear air conditioner, go to Step 15. If the vehicle does not have the optional rear air conditioner, go to Step 21. (15) Raise and support the vehicle. (16) Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heater and air conditioner (Fig. 7). Fig. 7 Underbody Connections 1 - SUCTION LINE EXTENSION 2 - LIQUID LINE EXTENSION 3 - TIE STRAP 4- HEATER LINE EXTENSIONS 5 - UNDERBODY LINES (17) Disconnect the suction line extension fitting from the underbody suction line fitting for the rear air conditioner. (18) Remove the seal from the underbody suction line fitting and discard. (19) Install plugs in, or tape over the opened suction line fittings. (20) Lower the vehicle. (21) Remove the suction line from the engine compartment. INSTALLATION The front air conditioner suction line includes the low side service port on a section of tubing located near the compressor. On models equipped with the optional rear air conditioner, the front air conditioner suction line also includes a suction line hose and tube extension that connects the front suction line to the suction line for the rear air conditioner. WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - WARNING - A/C PLUMBING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - FRONT - CAUTION - A/C PLUMBING). (1) Position the suction line into the engine compartment. (2) Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports. (3) Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings. (4) Reconnect the liquid line and suction line fittings to the expansion valve. (5) Install and tighten the nut that secures the suction line and liquid line fittings to the expansion valve. Tighten the nut to 23 N·m (17 ft. lbs.). (6) Engage the retainer that secures the suction line routing clip to the filter-drier mounting bracket on the side of the right front strut tower in the engine compartment. (7) Remove the tape or plugs from the compressor suction port and the suction line fitting. (8) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. (9) Reconnect the suction line fitting to the compressor suction port. (10) Install and tighten the nut that secures the suction line fitting to the compressor. Tighten the nut to 23 N·m (17 ft. lbs.). (11) Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. (12) Reinstall the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment. (13) Reconnect the battery negative cable. (14) If the vehicle is equipped with the optional rear air conditioner, go to Step 15. If the vehicle does not have the optional rear air conditioner, go to Step 21. (15) Raise and support the vehicle. (16) Remove the tape or plugs from the suction line extension fitting and the underbody suction line fitting (Fig. 38). (17) Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line fitting. 24 - 106 PLUMBING - REAR RS SUCTION LINE (Continued) (18) Reconnect the suction line extension fitting to the underbody suction line fitting. Tighten the fittings to 23 N·m (17 ft. lbs.). (19) Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heater and air conditioner. (20) Lower the vehicle. (21) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). (22) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING FRONT/REFRIGERANT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). Any kinks or sharp bends in the rear heater-A/C unit plumbing will reduce the capacity of the entire heating and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the plumbing connections is pressure-tight and leak free. UNDERBODY LINES DESCRIPTION The rear heater-A/C unit plumbing is used only on models with the optional rear heater-A/C unit. The formed metal rear heater-A/C unit suction line, liquid line, and heater lines are available for separate service replacement. The molded and straight heater hoses used on the rear heater-A/C unit can be serviced in the vehicle. Refer to Group 7 - Cooling System for the heater hose service procedures. OPERATION The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system (Fig. 8), (Fig. 9), (Fig. 11), (Fig. 10) and (Fig. 12). Fig. 9 Front Lines Connected to Rear Lines Fig. 8 Rear Heater and A/C Lines 1 - HEATER CONNECTION 2 - REAR A/C LINE BLOCK CONNECTION PLUMBING - REAR RS 24 - 107 UNDERBODY LINES (Continued) Fig. 12 Rear A/C Block Connection Fig. 10 Rear Heater Hose Connection 1 - CLEAN AREA AROUND BLOCK BEFORE REMOVAL 1 - REAR HEATER HOSE REMOVAL - REAR AIR CONDITIONING LINES Fig. 11 Rear heater hose quick connects 1 - INSERT 2 - QUICK CONNECT 3 - COMPRESS INSERT FOR REMOVAL REMOVAL REMOVAL - REAR HEATER LINES (1) Raise and support vehicle. (2) Pinch off rubber heater line hose. (3) Disconnect quick connect fitting at C-pillar. (4) Loosen one screw and remove the other screw at each of the three brackets holding the front of the line to the underbody. (5) Lower rear of line and drain coolant into a suitable container. (6) Loosen hose clamps at front of line and remove line from vehicle. (1) Recover A/C system. (2) Hoist and support vehicle. (3) Loosen one screw and remove the other screw at each of the three brackets holding the A/C lines to the underbody (Fig. 8). (4) Remove both A/C lines from the two rear retaining clamps, behind rear wheel. (5) Remove both compression fittings at front of A/C lines (Fig. 9). (6) Remove (1) bolt securing A/C lines to block located at A/C housing, behind rear wheel, and separate block (Fig. 12). (7) Remove rear wheel. (8) Separate ABS harness from flex hose clamps. (9) Remove heater lines from underbody brackets. (10) Pinch off rubber heater line hoses at front of vehicle. (11) Loosen hose clamps at front of heater lines and allow them to hang from vehicle. (12) Remove rear A/C lines from vehicle. (13) Remove nylon wedge holding lines into rear block (Fig. 13). 24 - 108 PLUMBING - REAR RS UNDERBODY LINES (Continued) INSTALLATION INSTALLATION - REAR HEATER LINES (1) Install line into underbody straps. (2) Install line into front hose and install hose clamp. (3) Connect quick fitting at rear of line. (4) Lower vehicle. (5) Fill cooling system (Refer to 7 - COOLING STANDARD PROCEDURE). INSTALLATION - REAR AIR CONDITIONING LINES Fig. 13 UNDERBODY LINE WEDGES 1 2 3 4 5 6 - O-RING DISCHARGE LINE NYLON WEDGE SEALING BLOCK VISE SUCTION LINE (1) Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved waxfree refrigerant oil. (2) Install A/C line into rear block with nylon wedge. (3) Install A/C lines into five underbody brackets. (4) Connect forward compression fittings. (5) Install bolt at sealing block to rear A/C housing. (6) Install ABS harness into clips. (7) Install heater hoses into underbody brackets. (8) Install lines into front hoses and install hose clamps. (9) Lower vehicle. (10) Evacuate and recharge system. (11) Fill cooling system (Refer to 7 - COOLING STANDARD PROCEDURE). DIESEL SUPPLEMENTAL HEATER - DCHA - BUX RS 24 - 109 DIESEL SUPPLEMENTAL HEATER - DCHA - BUX TABLE OF CONTENTS page page DIESEL SUPPLEMENTAL HEATER - DCHA BUX DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 109 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 109 DIAGNOSIS AND TESTING - DIESEL SUPPLEMENTAL HEATER - DCHA . . . . . . . . 110 EXHAUST TUBE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110 FUEL DOSING PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 111 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 111 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 111 FUEL LINE STANDARD PROCEDURE - CLEANING . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . HEATER UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . SUPPLEMENTAL DIESEL HEATER WIRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . AIR INTAKE PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . DIESEL SUPPLEMENTAL HEATER - DCHA - BUX OPERATION DESCRIPTION Vehicles equipped with the optional diesel engine are also equipped with a supplemental heater unit. This unit is mounted under the vehicle and operates similar to an oil fired furnace. The heater burns small amounts of fuel to provide additional heat to the coolant. Coolant is routed from the engine, to the supplemental heater, and then to the front heater core. This provides additional heat to the passenger compartment. The system is interfaced to the vehicles on-board computer systems and DRB-III diagnostics. . . . . 112 . . . . 112 . . . . 112 . . . . 114 . . . . 114 . . . . 115 . . . . 115 . . . . 115 . . . . 116 The supplemental heater unit is activated via the temperature slide control or knob on the vehicle HVAC control unit. If the control slide or knob is moved to or above the upper set point the heater is activated. The unit can operate in a full or partial load range as well as an idle mode all dependent on the engine coolant temperature. The heater unit will also turn off if the HVAC temperature control is lowered to less than the lower set point. The heater unit can take up to three minutes to completely shut down when either the heater temperature is set below the lower set point or the vehicle ignition is shut down. 24 - 110 DIESEL SUPPLEMENTAL HEATER - DCHA - BUX RS DIESEL SUPPLEMENTAL HEATER - DCHA - BUX (Continued) DIAGNOSIS AND TESTING - DIESEL SUPPLEMENTAL HEATER - DCHA The following table lists possible fault symptoms of diesel fueled heaters. SYMPTOM POSSIBLE CAUSES Smell of diesel fuel Check heater system integration in vehicle’s fuel system. Check fuel lines for leakage, kinks or obstructions. If OK, Inspect the inlet muffler, drain as necessary. Re-test the unit and re-inspect. Inspect the exhaust tube and heater unit for the presence of external fuel. If a volume is observed on the unit or in the exhaust tube or after draining and testing. Remove heater unit from vehicle and repair or replace components as required. Heater does not achieve full load operation. Check heater operation with DRB-III and replace components as required. Continuous white smoke from heater exhaust during combustion operation. Check heater operation with DRB-III and replace components as required. White smoke is typical in extreme weather conditions. Heater can not be switched off. Check heater operation with DRB-III and replace components as required. Heater does not operate. Diagnosis cabin heater ECU using the DRB-III and the procedures listed in Vehicle Performance under Cabin Heater Diagnosis in Group 18. Loss of coolant (Leakage) or heater develops smoke during combustion operation and exhaust has an extremely sweet smell. Inspect coolant hoses for leakage, kinks or loose hose connection. Inspect the exhaust tube assembly for continuous flow, if OK there is an internal heater leak and unit should be inspected and components should be replaced as required. Loss of fuel (dripping). Check heater system integration in vehicles fuel system. Check fuel line connection for leakage. If OK there is an internal leak and unit should be inspected and replaced as required. EXHAUST TUBE REMOVAL WARNING: THERE IS A POTENTIAL DANGER OF SKIN BURNS AS THE HEATER AND ITS COMPONENTS MAY BE VERY HOT. MAKE SURE THE HEATER IS ALLOWED TO COOL DOWN BEFORE ANY SERVICE WORK IS ATTEMPTED. WARNING: THERE IS A POTENTIAL DANGER OF SKIN BURNS AS THE EXHAUST SYSTEM MAY BE VERY HOT. MAKE SURE THE EXHAUST SYSTEM IS ALLOWED TO COOL DOWN BEFORE ANY SERVICE WORK IS ATTEMPTED ON THE CABIN HEATER. (1) Elevate vehicle on a lift taking note of the exhaust tube flexible section. (2) Remove the exhaust clamp at the flexible pipe and steel pipe connection (Fig. 1). (3) Remove the clamp at the flexible pipe connection and the heater unit housing (if required). (4) Remove the three screws holding the exhaust pipe to the body. (5) Remove the steel exhaust pipe from the vehicle. (6) Remove the flexible exhaust pipe from the vehicle (if required). INSTALLATION (1) Install the flexible exhaust pipe to the heater unit. Tighten mounting clamp. (2) Position the steel exhaust pipe to the flexible exhaust and install and tighten the mounting clamp. (3) Install the three exhaust pipe screws, adjust pipe placement as needed and tighten the screws. (4) Install the clamp to connect the steel exhaust pipe to the flexible exhaust pipe and tighten clamp. (5) Check exhaust pipe exhaust end placement and make any final adjustments. (6) Lower vehicle from lift. DIESEL SUPPLEMENTAL HEATER - DCHA - BUX RS 24 - 111 EXHAUST TUBE (Continued) Fig. 1 Diesel Cabin Heater Exhaust System 1 2 3 4 - Mounting screws (3) Steel heater exhaust pipe Exhaust clamp (2) Flexible heater exhaust pipe FUEL DOSING PUMP 5 - Heater and heater shield 6 - Exhaust pipe mounting clips (3) NOTE: Position and retain heater fuel line to prevent fuel leakage while servicing dosing pump. DESCRIPTION The dosing pump is a combined delivery, dosing and shut-off system for the fuel supply to the heater from the vehicles fuel tank. OPERATION The dosing pump is an electrically operated pump that receives its operation instructions from the supplemental heater electronic control module. The pump supplies diesel fuel from the fuel tank to the heater unit. REMOVAL The dosing pump is serviceable without removing the component from the vehicle. (1) Disconnect the rubber hose at the fuel line to heater fuel pump. Leave the rubber hose on the fuel line.(Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE - REMOVAL) (Fig. 2). (2) Disconnect the fuel line between the dosing pump and the heater unit. NOTE: Utilize an approved fuel storage container to catch any residual fuel. (3) Disconnect the electrical connector to the fuel pump by depressing the integral spring and pulling the connector away from the pump. (4) Remove the dosing pump from the rubber isolation. INSTALLATION (1) Mount the rubber isolation back onto the splash shield mounting flanges at two locations. (2) Connect fuel lines to the dosing pump and the heater unit. The connectors should point towards the heater fuel line. (3) Use aviation style clamps to attach the hose to the fuel pump nipples(Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE INSTALLATION). 24 - 112 DIESEL SUPPLEMENTAL HEATER - DCHA - BUX RS FUEL DOSING PUMP (Continued) Fig. 2 Dosing Pump Fuel Line 1 - Fuel Line 2 - Retaining Clamps (4) Connect the electrical connector to the fuel pump by depressing the integral spring and pushing the connector towards the dosing pump. Pull the connector towards the heater to verify the installation. (5) Verify function of the heater. FUEL LINE STANDARD PROCEDURE - CLEANING (1) Remove the cabin heater fuel line(Refer to 24 HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE - REMOVAL). (2) With cabin heater line removed from vehicle place a shop cloth on the fuel tank end of the fuel line to catch any residue, then apply a small amount of air pressure to the other end of the fuel line. (3) Check to see if air pressure is coming from the tank end of the line. If pressure is flowing unrestricted the line is clean. (4) If the line shows any signs of being restricted after air pressure is applied, then the fuel line should be replaced. (5) Install the cabin heater line(Refer to 24 HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE - INSTALLATION). (6) Verify function of the heater. 3 - Dosing Pump 4 - Heater Unit Air Intake Pipe REMOVAL (1) Elevate vehicle on a lift taking note of the heater exhaust tube flexible section. (2) Remove clamps on dosing pump end of fuel line and separate line from pump (Fig. 3). NOTE: Have an approved fuel holding device ready to capture any diesel fuel that drains from fuel line or heater unit. (3) Remove clamp from fuel line at fuel tank connection and separate line from tank. (4) Remove any retaining clips and remove line from vehicle. INSTALLATION WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE DCHA’S EXHAUST WHEN OPERATING THE DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH. RS DIESEL SUPPLEMENTAL HEATER - DCHA - BUX 24 - 113 FUEL LINE (Continued) Fig. 3 Dosing Pump Fuel Line 1 - Fuel Line 2 - Retaining Clamps WARNING: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: VERIFY THAT ALL DCHA FUEL LINES ARE SECURELY FASTENED TO THEIR RESPECTIVE COMPONENTS BEFORE PERFORMING THIS PROCEDURE. NOTE: Verify that there is more than 1/8 of a tank of fuel in the vehicle’s fuel tank before performing this procedure. Add fuel, if necessary. (1) Install heater fuel supply line to vehicle and install in fuel line retainers (2) Install fuel line connection at fuel tank and tighten connection. (3) Install fuel line at Dosing Pump and tighten connection. (4) Lower vehicle from lift. 3 - Dosing Pump 4 - Heater Unit Air Intake Pipe NOTE: Failure to prime the Dosing Pump after draining the DCHA fuel line will prevent DCHA heater activation during the first attempt to start the heater. This will also set a Diagnostic Trouble Code (DCT) in the DCHA Control’s memory. do not perform the Dosing Pump Priming procedure if an attempt was made to start the DCHA without priming the Dosing Pump first. This will put excess fuel in the DCHA Heater Module and cause smoke to emit from the DCHA exhaust pipe when heater activation occurs. (5) Connect the DRBIIIt to the Diagnostic Link Connector. (6) Turn the ignition to the on position. NOTE: Do not activate the Dosing Pump Prime more than one time. This will put excess fuel in the DCHA Heater Module an cause smoke to emit from the DCHA exhaust pipe when heater activation occurs. NOTE: A clicking noise heard coming from the Dosing Pump indicates that the pump is operational. 24 - 114 DIESEL SUPPLEMENTAL HEATER - DCHA - BUX RS FUEL LINE (Continued) (7) With the DRBIIIt in Cabin Heater, select System Tests and Dosing Pump Prime. Allow the Dosing Pump to run for the full 45 second cycle time. When the 45 second cycle is complete, press Page Back on the DRBIIIt key pad to exit the Dosing Pump Prime. The Dosing Pump priming procedure is now complete. HEATER UNIT REMOVAL WARNING: ALLOW THE DCHA TO COOL BEFORE PERFORMING A COMPONENT INSPECTION/REPAIR OR REPLACEMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WARNING: ALLOW THE EXHAUST SYSTEM TO COOL BEFORE PERFORMING A COMPONENT INSPECTION/REPAIR OR REPLACEMENT. FAILURE TO FOLLOW THESE INSTRUCTION MAY RESULT IN PERSONAL INJURY. (1) Elevate the vehicle on a hoist/lift taking note of heater exhaust tube flexible section. (2) Drain cooling system(Refer to 7 - COOLING STANDARD PROCEDURE). (3) Carefully open one hose to the underbody tube assembly and drain the remaining coolant. A salvage hose is a good idea to control the residual coolant, as flow will occur from both the heater and the hose and tube assemblies. (4) Remove the second hose from the underbody hose and tube assembly. (5) Loosen the hose and tube assembly from the toe-board cross member at two locations. (6) Disconnect the electrical connector from the body harness near the toe board cross member and rail. (7) Remove the wiring harness from the toe board cross member(Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT REMOVAL). (8) Open the fuel fill cap. Disconnect the rubber fuel hose between the body tube assembly and the fuel pump nipple at the body tube joint. A minimal amount of fuel may flow from the open port. NOTE: Utilize an approved fuel storage container to catch any residual fuel. (9) Loosen the two M8 fasteners at the rail. Take care to notice that the exhaust tube bracket tab is on top of the heater bracket. (10) Remove the heater exhaust tube flex section from the exhaust tube by loosening the M6 bolt of the clamp assembly. Remove the hose from the exhaust tube. Removal of the rail tube assembly may aid in this service operation.(Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/EXHAUST TUBE - REMOVAL). (11) Remove seat hex nut at the heater mounting flange to cross member. (12) Loosen the remaining M6 and M8 fasteners which mount the exhaust tube assembly to the vehicle. (a) Install a suitable cabin heater support device under the cabin heater and secure the cabin heater to the device. (13) Loosen the remaining three M6 fasteners to the cross members. (14) Remove the loosened fasteners that support the heater while supporting the weight of the heater. (15) Swing the unit mounting bracket from between the exhaust bracket and rail mounting location. Drain any residual coolant from the heater unit. (16) Lower the cabin heater and remove from the supporting device and place on a suitable work area. INSTALLATION (1) Install the unit mounting bracket between the exhaust bracket and the rail mounting location. (2) Install the fasteners that support the heater while supporting the weight of the heater. (3) Install the three M6 fasteners to the cross members. Tighten the M6 fasteners to 7 Nm (5 ft. lbs.). (4) Tighten the remaining M6 fasteners to 7 Nm (5 ft. lbs.) and the M8 fasteners to 23 Nm (17 ft. lbs.) which mount the exhaust tube assembly to the vehicle. (5) Install the seat hex nut at the heater mounting flange to the cross members. Tighten to 60 Nm (44 ft. lbs.) (6) Install the heater exhaust tube flex section to the exhaust tube by tightening the M6 bolt of the clamp assembly. Install the hose to the exhaust tube. (7) Tighten the two M8 fasteners at the rail to 23 Nm (17 ft. lbs.). Taking care so that the exhaust tube bracket tab is on the top of the heater bracket. (8) Install the wiring harness(Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/ HEATER UNIT - INSTALLATION). (9) Tighten the hose and tube assembly to the toeboard cross member at two locations. (10) Install the second hose to the underbody hose and tube assembly. (11) Connect the rubber fuel hose between the body tube assembly and the fuel pump nipple at the body tube joint. Close the fuel fill cap. RS DIESEL SUPPLEMENTAL HEATER - DCHA - BUX 24 - 115 HEATER UNIT (Continued) (12) Remove the heater unit support device from under the vehicle. (13) Lower vehicle from lift. (14) Refill cooling system(Refer to 7 - COOLING STANDARD PROCEDURE). (15) Verify function of the cabin heater. SUPPLEMENTAL DIESEL HEATER WIRING REMOVAL (1) Elevate vehicle on a lift taking note of the exhaust tube flexible section. (2) Unplug connector from vehicle wiring harness to cabin heater harness. (3) Unplug connector from cabin heater harness to dosing pump connector. (4) Unplug two connectors from cabin heater harness to cabin heater controller connectors. (5) Remove two wiring harness connectors from underbody. (6) Remove two wiring harness connectors from cabin heater shield. (7) Carefully route the cabin heater harness to the left side between the cabin heater unit and the cabin heater shield. AIR INTAKE PIPE REMOVAL NOTE: Heater air intake tube is part of an assembly that includes the heater cooling intake and return pipes. If heater air intake tube requires removal or replacement the entire assembly will require removal/replacement. (1) Drain cooling system(Refer to 7 - COOLING STANDARD PROCEDURE). (2) Remove clamps from the heater tubes at the lower heater port and the lower EGR connector which are located under the hood. (3) Remove the retaining clamp at the heater air intake muffler connection(Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/INLET MUFFLER - REMOVAL). (4) Remove the clamp at the flexible tube to steel tube connection (Fig. 4). INSTALLATION (1) Carefully route the cabin heater harness from the left side of the cabin heater between the cabin heater unit and the cabin heater shield. (2) Install the two wiring harness retaining connectors to the cabin heater shield. (3) Route the wiring harness along the underside of the vehicle and install the two wiring harness retaining connectors. (4) Plug the two connectors from the cabin heater harness to the cabin heater controller. (5) Plug the connector to the cabin heater harness to the dosing pump connector. (6) Plug the connector from the vehicle wiring harness to the cabin heater harness. (7) Lower the vehicle. (8) Verify function of the cabin heater. Fig. 4 FLEXIBLE AIR INTAKE LINE 1 2 3 4 5 6 - HEATER UNIT AND SPLASH SHIELD DOSING PUMP DOSING PUMP FUEL LINE FLEXIBLE INTAKE LINE CLAMP STEEL INTAKE PIPE 24 - 116 DIESEL SUPPLEMENTAL HEATER - DCHA - BUX RS AIR INTAKE PIPE (Continued) (5) Remove the two retaining screws and remove pipe assembly (Fig. 5). Fig. 5 AIR INTAKE AND HEATER PIPE ASSEMBLY 1 2 3 4 5 - INTAKE TUBE AIR INTAKE INTAKE PIPE RETAINING SCREWS INTAKE HEATER LINE RETURN HEATER LINE INSTALLATION (1) Install the air intake pipe assembly and install the two retaining screws. Tighten the screws to 7 Nm ( 5 ft. lbs.). (2) Attach the steel tube to the flexible tube and position and then tighten the retaining clamp. (3) Install the flexible tube to the heater air intake muffler and install and tighten the retaining clamp. (4) Install the heater tubes to the lower heater connection and the lower EGR cooler connection and tighten the retaining clamps. (5) Lower the vehicle. (6) Refill the cooling system(Refer to 7 - COOLING - STANDARD PROCEDURE). (7) Verify function of the heater unit. FUEL SYSTEM RS 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page FUEL DELIVERY ..........................1 page FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 16 FUEL DELIVERY TABLE OF CONTENTS page FUEL DELIVERY DESCRIPTION DESCRIPTION ..................... DESCRIPTION - FFV REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE . . . . STANDARD PROCEDURE - DRAINING FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS FUEL SYSTEM PRESSURE ........... TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL FILTER REMOVAL .......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL SENDING UNIT / SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL .......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . FUEL LINES DESCRIPTION - FUEL LINES/HOSES AND CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - HOSES AND CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PRESSURE REGULATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...2 ...2 ...2 ...2 ...2 ...2 ...3 ...3 ...3 ...4 ...4 . . . . . . . . .4 .4 .4 .6 ...6 ...6 ...7 page REMOVAL .............................7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FUEL PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FUEL PUMP MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FUEL RAIL REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . 10 INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . 10 FUEL TANK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 FUEL TANK FILLER TUBE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 INLET FILTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 QUICK CONNECT FITTING STANDARD PROCEDURE - QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 14 - 2 FUEL DELIVERY FUEL DELIVERY DESCRIPTION DESCRIPTION The front wheel drive car uses a plastic fuel tank located rear center of the vehicle. The Fuel Delivery System consists of: the following items: • Electric fuel pump module • Fuel filter • Tubes/lines/hoses • Fuel injectors The in-tank fuel pump module contains the fuel pump. The pump is serviced as part of the fuel pump module. Refer to Fuel Pump Module. The fuel filter is replaceable, it is mounted on the outside, on top of, the fuel tank. Refer to the Maintenance Schedules in the Introduction section of this manual for recommended fuel filter replacement intervals. DESCRIPTION - FFV REPLACEMENT PARTS Many components in a Flexible Fuel Vehicle (FFV) are designed to be compatible with ethanol. Always be sure that the vehicle is serviced with correct ethanol compatible parts. CAUTION: Replacing fuel system components with non-ethanol compatible components can damage your vehicle and may void the warranty. OPERATION The fuel system provides fuel pressure by an in-tank pump module. The PCM controls the operation of the fuel system by providing battery voltage to the fuel pump through the fuel pump relay. The PCM requires only three inputs and a good ground to operate the fuel pump relay. The three inputs are: RS • Ignition voltage • Crankshaft Position (CKP) sensor • Camshaft Position (CMP) sensor DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM (Refer to Appropriate Diagnostic Information) STANDARD PROCEDURE STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE (1) Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. (2) Start and run engine until it stalls. (3) Attempt restarting engine until it will no longer run. (4) Turn ignition key to OFF position. (5) Return fuel pump relay to PDC. (6) One or more Diagnostic Trouble Codes (DTC’s) may have been stored in PCM memory due to fuel pump relay removal. The DRB IIIt scan tool must be used to erase a DTC. STANDARD PROCEDURE - DRAINING FUEL TANK (1) Release fuel system pressure, refer to the Fuel System Release Procedure in this section. (2) Insert a 1/4 inch siphon (max. O. D. 5/16) hose from a portable fuel siphoning tank through the fuel filler neck opening into the fuel tank. Hose most have a 30 degree angle cut on the end to bypass the check valve in the end of the filler neck. Refer to the siphoning tank’s Manufacturing Instructions. (3) Drain fuel from fuel tank into siphoning tank. FUEL DELIVERY RS 14 - 3 FUEL DELIVERY (Continued) SPECIFICATIONS FUEL SYSTEM PRESSURE 400 kpa ±34 kpa (58 psi ± 5 psi) TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Fuel Filler Neck Clamp 3.3 30 Fuel Rail 2.4L 22 200 Fuel Rail 3.3/3.8L 11.8 105 Fuel Tank Strap 54 Fuel Tank T Strap 28.2 40 250 Fuel Filter Bolt 4.5 40 SPECIAL TOOLS FUEL Fuel Line Adapter 1/4 Pressure Gauge Assembly C–4799–B O2S (Oxygen Sensor) Remover/Installer—C-4907 Fuel Pressure Test Adapter 6539 O2S(Oxygen Sensor) Remover/Installer - 8439 Spanner Wrench 6856 14 - 4 FUEL DELIVERY FUEL FILTER REMOVAL (1) Release fuel pressure, refer to the Fuel release procedure in this section. (2) Disconnect the negative battery cable. (3) Raise vehicle and support. (4) Support the fuel tank with a transmission jack. (5) Remove fuel line from the front of the tank. (6) Remove ground strap (7) Remove the inboard side of the fuel tank straps and front T strap fastner. (8) Lower the tank about 6 inches (Fig. 1). RS FUEL LEVEL SENDING UNIT / SENSOR DESCRIPTION The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. OPERATION Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted. REMOVAL Remove fuel pump module. Refer to Fuel Pump Module in this section. (1) Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module electrical connector (Fig. 2) . NOTE: The pump module harness on TOP of flange is not serviceable or removable. Fig. 1 FUEL FILTER (9) Remove fuel lines from the fuel pump module. (10) Remove fuel filter from tank. INSTALLATION (1) Install fuel filter to tank. Tighten bolt to 4.5 N·m (40 in. lbs.) (2) Install fuel lines to the fuel pump module (Fig. 1). (3) Raise tank into position. (4) Install the fuel tank straps.Tighten bolt for main straps to 54 N·m (40 ft. lbs.) and the T strap bolt to 28.2 N·m (250 in. lbs.) (5) Install the ground strap (6) Connect the fuel line at the front of the tank. (7) Lower vehicle. (8) Connect the negative battery cable. (9) Pressurize the fuel system with the DRBIIIt and check for leaks. Fig. 2 Fuel Pump/Level Sensor Electrical Connector 1 - ELECTRICAL CONNECTOR 2 - RETAINING TAB FUEL DELIVERY RS 14 - 5 FUEL LEVEL SENDING UNIT / SENSOR (Continued) (2) Pull off the locking wedge. (3) Using a small screwdriver lift locking finger away from terminal and push terminal out of connector (Fig. 3). (5) Insert a screwdriver between the fuel pump module and the top of the level sensor housing (Fig. 5) . Push level sensor down slightly. Fig. 3 Wire Terminal Locking Finger 1 - LOCKING FINGER 2 - WIRE TERMINAL Fig. 5 Loosening Level Sensor (4) Push level sensor signal and ground terminals out of the connector (Fig. 4). 1 - LEVEL SENSOR 2 - PRY DOWN ON LEVEL SENSOR (6) Slide level sensor wires through opening fuel pump module (Fig. 6). Fig. 4 Removing Wires From 1 2 3 4 - FUEL PUMP FEED (RED B+) LEVEL SENSOR SIGNAL LEVEL SENSOR GROUND FUEL PUMP GROUND (BK) Fig. 6 Level Sensor Removal/Installation 1 - OPENING IN MODULE 2 - FUEL LEVEL SENSOR (7) Slide level sensor out of installation channel in module. 14 - 6 FUEL DELIVERY RS FUEL LEVEL SENDING UNIT / SENSOR (Continued) INSTALLATION (1) Insert level sensor wires into bottom of opening in module. (2) Wrap wires into groove in back of level sensor (Fig. 7) . (7) Install fuel pump module. Refer to Fuel Pump Module in this section. FUEL LINES DESCRIPTION - FUEL LINES/HOSES AND CLAMPS Also refer to Quick-Connect Fittings. 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 SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP. Fig. 7 Groove in Back Side of Level Sensor 1 - WRAP WIRES IN GROOVE 2 - REAR VIEW OF LEVEL SENSOR (3) While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place (Fig. 8) . Ensure tab at bottom of sensor locks in place. 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, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected 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 high-pressure fuel leaks. Use new original equipment type hose clamps. STANDARD PROCEDURE - HOSES AND CLAMP Fig. 8 Installation Channel 1 - CHANNEL FOR LEVEL SENSOR 2 - PUMP MODULE (4) Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. (5) Install locking wedge on connector. (6) Push connector up into bottom of fuel pump module electrical connector. 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 N·m (10 in. lbs.) torque. Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure and FUEL DELIVERY RS 14 - 7 FUEL LINES (Continued) 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. FUEL PRESSURE REGULATOR OPERATION The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at approximately 400 ±34 kPa (58 ±5 psi). The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down on the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of fuel pressure required to open the return port. The pressure regulator is a mechanical device that is NOT controlled by the PCM or engine vacuum. REMOVAL The fuel pressure regulator is part of the fuel pump module (Fig. 9). Remove the fuel pump module from the fuel tank to access the fuel pressure regulator. Refer to the Fuel Pump Module removal in this section. (1) Spread tangs on pressure regulator retainer. (2) Pry fuel pressure regulator out of housing. (3) Ensure both upper and lower O-rings were removed with regulator. INSTALLATION The fuel pressure regulator is part of the fuel pump module. Remove the fuel pump module from the fuel tank to access the fuel pressure regulator. Refer to the Fuel Pump Module removal in this section. (1) Lightly lubricate the O-rings with clean engine oil and place them into opening in pump module (Fig. 9). (2) Push regulator into opening in pump module. (3) Fold tangs on regulator retainer over tabs on housing. Fig. 9 Fuel Pressure Regulator O-rings 1 - UPPER O-RING 2 - LOWER 0-RING FUEL PUMP DESCRIPTION The electric fuel pump is located in and is part of the fuel pump module. It is a positive displacement, gerotor type, immersible pump with a permanent magnet electric motor. The fuel pump module is suspended in fuel in the fuel tank. OPERATION The pump draws fuel through a strainer and pushes it through the motor to the outlet. The pump contains a check valve. The valve, in the pump outlet, maintains pump pressure during engine off conditions, for a short while. It is normal for fuel pressure to drop to zero after cooldown. The fuel pump relay provides voltage to the fuel pump. The fuel pump has a maximum deadheaded pressure output of approximately 880 kPa (130 psi). The regulator adjusts fuel system pressure to approximately 400 kpa ±34 kpa (58 psi ± 5 psi). NOTE: Checkvalve maintains volume of fuel in the rail and lines, not pressure. 14 - 8 FUEL DELIVERY FUEL PUMP MODULE DESCRIPTION The fuel pump module is installed in the top of the fuel tank (Fig. 10) . RS tional description of the fuel pump refer to fuel Pump Relay—PCM Output. ELECTRICAL PUMP REPLACEMENT The electric fuel pump is not serviceable. If the fuel pump or electrical wiring harness needs replacement, the complete fuel pump module must be replaced. Perform the Fuel System Pressure Release procedure before servicing the fuel pump. REMOVAL 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. Fig. 10 Fuel Pump Module 1 2 3 4 - INLET STRAINER FUEL RESERVOIR FUEL PRESSURE REGULATOR FUEL LEVEL SENSOR 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 The inlet strainer, fuel pressure regulator and fuel level sensor are the only serviceable items. If the fuel pump or electrical wiring harness requires service, replace the fuel pump module. The electric fuel pump is located in and is part of the fuel pump module. It is a positive displacement, gerotor type, immersible pump with a permanent magnet electric motor. (1) Remove fuel filler cap and perform Fuel System Pressure Release procedure. (2) Disconnect negative cable from auxiliary jumper terminal. (3) Drain fuel tank, refer to the Fuel Tank procedure in the Fuel Delivery section. (4) Remove fuel tank, refer to the Fuel Tank removal section. (5) Clean top of tank to remove loose dirt and debris. (6) Using a brass punch and hammer remove locknut to release pump module (Fig. 11). OPERATION The pump draws fuel through a strainer and pushes it through the motor to the outlet. The pump contains one check valve. The check valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump relay provides voltage to the fuel pump. The fuel pump has a maximum deadheaded pressure output of approximately 880 kPa (130 psi). The regulator adjusts fuel system pressure to approximately 400 ±34 kPa (58 ±5 psi). FUEL PUMP ELECTRICAL CONTROL Voltage to operate the electric pump is supplied through the fuel pump relay. For an electrical opera- Fig. 11 FUEL PUMP MODULE LOCKING RING FUEL DELIVERY RS 14 - 9 FUEL PUMP MODULE (Continued) WARNING: THE FUEL RESERVOIR OF THE FUEL PUMP MODULE DOES NOT EMPTY OUT WHEN THE TANK IS DRAINED. THE FUEL IN THE RESERVOIR MAY SPILL OUT WHEN THE MODULE IS REMOVED. (7) Remove fuel pump module and O-ring from tank (Fig. 12). Discard O-ring. Fig. 13 FUEL RAIL AND INJECTORS 2.4L 1 - Fuel Injectors 2 - Fuel Rail Fig. 12 Fuel Pump Module Removal 1 - FUEL PUMP MODULE 2 - O-RING INSTALLATION (1) Wipe seal area of tank clean and place a new O-ring seal in position on pump. (2) Position fuel pump module in tank. (3) Tighten locknut using a brass punch and hammer to install the locknut (Fig. 11). (4) Install fuel tank, refer to the Fuel Tank installation section. (5) Lower vehicle. (6) Connect negative cable battery. (7) Fill fuel tank. Check for leaks. (8) Install fuel filler cap. FUEL RAIL REMOVAL REMOVAL - 2.4L (1) Perform fuel system pressure release procedure before servicing or starting repairs. Refer to Fuel System Pressure Release Procedure in this section. (2) Disconnect negative cable from battery. (3) Disconnect the wiring connectors for fuel injectors harness (Fig. 13). (4) Remove wiring harness from brackets. (5) Disconnect the connectors from the fuel injectors. (6) Remove harness from vehicle. (7) Remove fuel hose quick connect fitting from the chassis tube. Refer to Fuel Hoses, Clamps and Quick Connect Fittings in this Section. Place a shop towel under the connections to absorb any fuel spilled from the fitting. WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE. (8) Remove fuel rail attaching bolts. (9) Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports. REMOVAL - 3.3/3.8L (1) Perform fuel system pressure release procedure before servicing or starting repairs. Refer to Fuel System Pressure Release Procedure in this section. (2) Disconnect negative cable from battery. (3) Remove upper intake manifold, refer to the Engine/Manifolds/Upper Intake for more information.. (4) Cover intake manifold with suitable cover when servicing. (5) Remove the fuel hose quick connect fitting from the chassis tube. Refer to Fuel Hoses, Clamps and Quick Connect Fittings in this Section. WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE. (6) Remove the fuel rail attaching bolts (Fig. 14). (7) Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports. 14 - 10 FUEL DELIVERY RS FUEL RAIL (Continued) (7) Install fuel hose quick connector fitting to chassis tubes. Refer to Fuel Hoses, Clamps and Quick Connect Fittings in this Section. Push the fitting onto the chassis tube until it clicks into place. Pull on the fitting to ensure complete insertion. (8) Connect negative cable to battery. (9) Use the DRBIIIt scan tool to pressurize the fuel system. Check for leaks. FUEL TANK DESCRIPTION Fig. 14 FUEL INJECTORS 3.3/3.8L The fuel tank is constructed of a plastic material. Its main functions are for fuel storage and for placement of the fuel pump module. The tank is made from High density Polyethylene (HDPE) material.If equipped with ORVR (Onboard Refueling Vapor Recovery) it has been added to the fuel tank to control refueling vapor emissions. INSTALLATION OPERATION INSTALLATION - 2.4L All models pass a full 360 degree rollover test without fuel leakage. To accomplish this, fuel and vapor flow controls are required for all fuel tank connections. All models are equipped with either one or two rollover valves mounted into the top of the fuel tank (or pump module). An evaporation control system is connected to the rollover valve(s)/control valve(Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/ ORVR - OPERATION) to reduce emissions of fuel vapors into the atmosphere, when the tank is vented due to vapor expansion in the tank. When fuel evaporates from the fuel tank, vapors pass through vent hoses or tubes to a charcoal canister where they are temporarily held. When the engine is running, the vapors are drawn into the intake manifold. In addition, fuel vapors produced during vehicle refueling are allowed to pass through the vent hoses/tubes to the charcoal canister(s) for temporary storage (prior to being drawn into the intake manifold). All models are equipped with a self-diagnosing system using a Leak Detection Pump (LDP). Refer to the Emission Control System for additional information. (1) Ensure injector holes are clean. Replace O-rings if damaged. (2) Lubricate injector O-rings with a drop of clean engine oil to ease installation. (3) Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports. (4) Install the fuel rail mounting bolts. Tighten bolts to 22 N·m (200 in. lbs.) torque. (5) Connect the connectors to the fuel injectors. (6) Install wiring harness to brackets. (7) Connect the wiring connectors to fuel injectors harness (Fig. 13). (8) Connect negative battery cable. (9) Use the DRBIIIt scan tool to pressurize the fuel system. Check for leaks. INSTALLATION - 3.3/3.8L (1) Ensure injector holes are clean. Replace O-rings if damaged. (2) Lubricate injector O-rings with a drop of clean engine oil to ease installation. (3) Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports. (4) Install the fuel rail mounting bolts. Tighten bolts to 22 N·m (200 in. lbs.) torque. (5) Remove covering on lower intake manifold and clean surface. (6) Install the Upper Intake Manifold, refer to Engine/Manifolds/Upper Intake for more information. INLET CHECK VALVE All vehicles have an inlet check valve on the inside of the fuel tank at the filler inlet The valve prevents fuel from splashing back on customer during vehicle refueling. The valve is a non-serviceable item. FUEL DELIVERY RS 14 - 11 FUEL TANK (Continued) REMOVAL Fig. 15 Fuel Tank 1 2 3 4 5 6 - ROLLOVER VALVE FUEL FILLER INLET ROLLOVER VALVE GROUND STRAP FUEL FILTER FUEL PUMP MODULE (1) Remove fuel filler cap and perform Fuel System Pressure Release procedure (Fig. 15). (2) Disconnect negative cable from battery. (3) Insert fuel siphon hose into fuel filler neck and push it into the tank. (4) Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container. (5) Raise vehicle on hoist and support. (6) Use a transmission jack to support fuel tank. Remove bolts from fuel tank straps. (7) Lower tank slightly. (8) Disconnect the fuel filler vent tube. Squeeze tabs and pull apart (Fig. 16). (9) Disconnect the fuel fill hose at the fuel tank filler metal tube NOT AT THE FUEL TANK (Fig. 16). (10) Disconnect fuel line and vapor line at the front of the fuel tank. The fuel pump module electrical connector has a retainer that locks it in place. (11) Slide fuel pump module electrical connector lock to unlock (Fig. 17). (12) Push down on connector retainer (Fig. 18) and pull connector off module. (13) Lower tank from vehicle. Remove fuel filler vent tube from frame (Fig. 19). Fig. 16 FUEL FILLER AND VENT TUBE 1 - Filler Tube 2 - Vent Tube Fig. 17 Fuel Line Retainers and Pump Connector Lock 1 - PUSH 2 - CONNECTOR LOCK 3 - QUICK CONNECT RETAINERS INSTALLATION (1) Position fuel tank on transmission jack. Connect rollover valve hose. Connect fuel filler tube vent hose and tighten clamp. (2) Raise tank into position and carefully work filler metal tube into the rubber hose on fuel tank. A light coating of clean engine oil on the tube end may be used to aid assembly. 14 - 12 FUEL DELIVERY RS FUEL TANK (Continued) (7) Lubricate the fuel supply line with clean 30 weight engine oil, install the quick connect fuel fitting. Refer to Tube/Fitting Assembly in the Fuel Delivery section of this section. (8) Attach filler vent line to filler tube. Pull on connector to make sure of connection. (9) Fill fuel tank, replace cap, and connect battery negative cable. (10) Use the DRBIIIt scan tool to pressurize the fuel system. Check for leaks. FUEL TANK FILLER TUBE REMOVAL Fig. 18 Pump Module Connector Retainer and Lock 1 - PUSH DOWN ON RETAINER 2 - CONNECTOR LOCK (1) (2) (3) (4) (5) Disconnect the negative battery cable. Remove the 3 screws at the filler door. Raise and support vehicle Remove the left rear tire. Remove the splash shield (Fig. 20). Fig. 19 VENT HOSE (3) Feed filler vent line thru frame rail. Careful not to cross lines. (4) Tighten strap bolts to 54 N·m (40 ft. lbs.) torque. Tighten T strap bolt to 28.2 N·m (250 in. lbs.). Remove transmission jack. (5) Tighten filler hose clamp to 3.3 N·m (30 in. lbs.). CAUTION: Ensure straps are not twisted or bent before or after tightening strap nuts. (6) Connect fuel pump/module electrical connector. Place retainer in locked position. Fig. 20 FUEL FILLER TUBE AND VENT TUBE (6) (7) (8) (9) Remove the canister from filler tube (Fig. 21). Disconnect the vent at the top of the filler tube. Remove the ground strap. Remove filler tube at tank. INSTALLATION (1) Install filler tube to tank (Fig. 20). (2) Install the ground strap. (3) Connect the vent at the top of the filler tube. FUEL DELIVERY RS 14 - 13 FUEL TANK FILLER TUBE (Continued) Fig. 22 Inlet 1 - TABS 2 - INLET STRAINER QUICK CONNECT FITTING Fig. 21 FUEL TUBE VENT CANISTER (4) (5) (6) (7) (8) (9) Install the 3 screws at the filler door. Install the canister from filler tube (Fig. 21). Install the splash shield. Install the left rear tire. lower vehicle. Connect the negative battery cable. INLET FILTER REMOVAL (1) Remove fuel pump module. Refer to Fuel Pump Module Removal in this section. (2) Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer (Fig. 22). (3) Remove strainer O-ring from the fuel pump reservoir body. (4) Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION (1) Lubricate the strainer O-ring with clean engine oil. (2) Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. (3) Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. (4) Install fuel pump module. Refer to Fuel Pump Module Installation in this section. STANDARD PROCEDURE - QUICK-CONNECT FITTINGS REMOVAL 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. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. (1) Perform Fuel Pressure Release Procedure. Refer to the Fuel Pressure Release Procedure in this section. (2) Disconnect negative cable from battery or auxiliary jumper terminal. (3) Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube. INSTALLATION CAUTION: 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 quickconnect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. (1) Using a clean lint free cloth, clean the fuel tube nipple and retainer. (2) Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean engine oil. 14 - 14 FUEL DELIVERY RS QUICK CONNECT FITTING (Continued) (3) Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. (4) The plastic quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed (Fig. 23). Do not rely upon the audible click to confirm a secure connection. Fig. 24 Typical Two-Tab Type Quick-Connect Fitting 1 - TAB(S) 2 - QUICK-CONNECT FITTING Fig. 23 Plastic Quick-Connect Fitting/Fuel Tube Connection 1 2 3 4 - WINDOW TAB (2) EAR SHOULDER (ON TUBE) (5) Connect negative cable to battery or auxiliary jumper terminal. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for several minutes, until the test is stopped, or until the ignition switch is turned to the Off position. (6) Use the DRB IIIt scan tool ASD 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 (Fig. 24). 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 IN THIS GROUP. DISCONNECTION/CONNECTION (1) Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure in this group. (2) Disconnect negative battery cable from battery or auxiliary jumper terminal. (3) Clean fitting of any foreign material before disassembly. (4) To disconnect quick-connect fitting, squeeze plastic retainer tabs (Fig. 24) against sides of quickconnect 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 quickconnect 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. FUEL DELIVERY RS 14 - 15 QUICK CONNECT FITTING (Continued) (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 pulling on fuel tube and fitting (15-30 lbs.). (9) Connect negative cable to battery or auxiliary jumper terminal. (10) Use the DRB IIIt scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. 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. 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 SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP. PLASTIC RETAINER RING TYPE FITTING This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 25) usually black in color. Fig. 25 Plastic Retainer Ring Type Fitting 1 2 3 4 5 6 7 8 - FUEL TUBE QUICK CONNECT FITTING PUSH PLASTIC RETAINER PUSH PUSH PUSH PUSH DISCONNECTION/CONNECTION (1) Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure in this section. (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 quickconnect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (Fig. 25). 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 pulling on fuel tube and fitting (15-30 lbs.). (10) Connect negative battery cable to battery or auxiliary jumper terminal. (11) Use the DRB IIIt scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. 14 - 16 FUEL INJECTION RS FUEL INJECTION TABLE OF CONTENTS page FUEL INJECTION OPERATION OPERATION - INJECTION SYSTEM . . OPERATION - MODES OF OPERATION FUEL CORRECTION or ADAPTIVE MEMORIES . . . . . . . . . . . . . . . . . . . . . PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) BUS . . . . . . . . . . . . SYSTEM DIAGNOSIS . . . . . . . . . . . . . SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . ACCELERATOR PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . CRANKSHAFT POSITION SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - 2.4L . . . . . . . . . . . . . . . ENGINE SPEED SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . FUEL INJECTOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . . . . REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . INSTALLATION INSTALLATION - 2.4L ............. INSTALLATION - 3.3/3.8L . . . . . . . . . . . FUEL PUMP RELAY DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . IDLE AIR CONTROL MOTOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . 17 . . . . . 19 . . . . . 20 . . . . . 21 . . . . . 21 . . . . . 22 . . . . . 22 . . . . . 23 . . . . . . . . . . . . . . . . . 23 . 24 . 24 . 24 . . . . . 24 . . . . . 25 . . . . . 25 . . . . . 25 . . . . . 25 . . . . . 26 . . . . . 26 . . . . . 26 . . . . . 27 . . . . . 27 . . . . . 27 . . . . . 27 . . . . . 28 page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . INLET AIR TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . MAP SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION - 2.4L ............... INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . O2 SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL REMOVAL - UPSTREAM 1/1 - 2.4L . . . . . REMOVAL - UPSTREAM 1/1 - 3.3/3.8L .. REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/ 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION - UPSTREAM 1/1 - 2.4L . . INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L INSTALLATION DOWNSTREAM 2/1 2.4/3.3/3.8L . . . . . . . . . . . . . . . . . . . . . . . THROTTLE BODY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . THROTTLE CONTROL CABLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . THROTTLE POSITION SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . . 28 . . . 28 . . . 28 . . . 29 . . . 29 . . . 30 . . . 30 . . . 30 . . . 30 . . . 30 . . . 31 . . . 32 . . . 32 . . . 32 . . . 32 . . 33 . . . 33 . . . . . . . . . 33 . 33 . 34 . 34 . . . 34 . . . 34 . . . . . . . . . 35 . 35 . 35 . 35 RS FUEL INJECTION OPERATION OPERATION - INJECTION SYSTEM All engines used in this section have a sequential Multi-Port Electronic Fuel Injection system. The MPI system is computer regulated and provides precise air/fuel ratios for all driving conditions. The Powertrain Control Module (PCM) operates the fuel injection system. The PCM regulates: • Ignition timing • Air/fuel ratio • Emission control devices • Cooling fan • Charging system • Idle speed • Vehicle speed control Various sensors provide the inputs necessary for the PCM to correctly operate these systems. In addition to the sensors, various switches also provide inputs to the PCM. The PCM can adapt its programming to meet changing operating conditions. Fuel is injected into the intake port above the intake valve in precise metered amounts through electrically operated injectors. The PCM fires the injectors in a specific sequence. Under most operating conditions, the PCM maintains an air fuel ratio of 14.7 parts air to 1 part fuel by constantly adjusting injector pulse width. Injector pulse width is the length of time the injector is open. The PCM adjusts injector pulse width by opening and closing the ground path to the injector. Engine RPM (speed) and manifold absolute pressure (air density) are the primary inputs that determine injector pulse width. OPERATION - MODES OF OPERATION As input signals to the PCM change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for Wide Open Throttle (WOT). There are several different modes of operation that determine how the PCM responds to the various input signals. There are two different areas of operation, OPEN LOOP and CLOSED LOOP. During OPEN LOOP modes the PCM receives input signals and responds according to preset PCM programming. Inputs from the upstream and downstream heated oxygen sensors are not monitored during OPEN LOOP modes, except for heated oxygen FUEL INJECTION 14 - 17 sensor diagnostics (they are checked for shorted conditions at all times). During CLOSED LOOP modes the PCM monitors the inputs from the upstream and downstream heated oxygen sensors. The upstream heated oxygen sensor input tells the PCM if the calculated injector pulse width resulted in the ideal air-fuel ratio of 14.7 to one. By monitoring the exhaust oxygen content through the upstream heated oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. For the PCM to enter CLOSED LOOP operation, the following must occur: (1) Engine coolant temperature must be over 35°F. • If the coolant is over 35°F the PCM will wait 38 seconds. • If the coolant is over 50°F the PCM will wait 15 seconds. • If the coolant is over 167°F the PCM will wait 3 seconds. (2) For other temperatures the PCM will interpolate the correct waiting time. (3) O2 sensor must read either greater than 0.745 volts or less than 0.29 volt. (4) The multi-port fuel injection systems has the following modes of operation: • Ignition switch ON (Zero RPM) • Engine start-up • Engine warm-up • Cruise • Idle • Acceleration • Deceleration • Wide Open Throttle • Ignition switch OFF (5) The engine start-up (crank), engine warm-up, deceleration with fuel shutoff and wide open throttle modes are OPEN LOOP modes. Under most operating conditions, the acceleration, deceleration (with A/C on), idle and cruise modes, with the engine at operating temperature are CLOSED LOOP modes. IGNITION SWITCH ON (ZERO RPM) MODE When the ignition switch activates the fuel injection system, the following actions occur: • The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM determines basic fuel injector pulse width from this input. • The PCM determines atmospheric air pressure from the MAP sensor input to modify injector pulse width. When the key is in the ON position and the engine is not running (zero rpm), the Auto Shutdown (ASD) and fuel pump relays de-energize after approximately 14 - 18 FUEL INJECTION RS FUEL INJECTION (Continued) 1 second. Therefore, battery voltage is not supplied to the fuel pump, ignition coil, fuel injectors and heated oxygen sensors. ENGINE START-UP MODE This is an OPEN LOOP mode. If the vehicle is in park or neutral (automatic transaxles) or the clutch pedal is depressed (manual transaxles) the ignition switch energizes the starter relay. The following actions occur when the starter motor is engaged. • If the PCM receives the camshaft position sensor and crankshaft position sensor signals, it energizes the Auto Shutdown (ASD) relay and fuel pump relay. If the PCM does not receive both signals within approximately one second, it will not energize the ASD relay and fuel pump relay. The ASD and fuel pump relays supply battery voltage to the fuel pump, fuel injectors, ignition coil, (EGR solenoid and PCV heater if equipped) and heated oxygen sensors. • The PCM energizes the injectors (on the 69° degree falling edge) for a calculated pulse width until it determines crankshaft position from the camshaft position sensor and crankshaft position sensor signals. The PCM determines crankshaft position within 1 engine revolution. • After determining crankshaft position, the PCM begins energizing the injectors in sequence. It adjusts injector pulse width and controls injector synchronization by turning the individual ground paths to the injectors On and Off. • When the engine idles within ±64 RPM of its target RPM, the PCM compares current MAP sensor value with the atmospheric pressure value received during the Ignition Switch On (zero RPM) mode. Once the ASD and fuel pump relays have been energized, the PCM determines injector pulse width based on the following: • MAP • Engine RPM • Battery voltage • Engine coolant temperature • Inlet/Intake air temperature (IAT) • Throttle position • The number of engine revolutions since cranking was initiated During Start-up the PCM maintains ignition timing at 9° BTDC. ENGINE WARM-UP MODE This is an OPEN LOOP mode. The following inputs are received by the PCM: • Manifold Absolute Pressure (MAP) • Crankshaft position (engine speed) • Engine coolant temperature • Inlet/Intake air temperature (IAT) • Camshaft position • Knock sensor • Throttle position • A/C switch • Battery voltage • Vehicle speed • Speed control • O2 sensors The PCM adjusts injector pulse width and controls injector synchronization by turning the individual ground paths to the injectors On and Off. The PCM adjusts ignition timing and engine idle speed. Engine idle speed is adjusted through the idle air control motor. CRUISE OR IDLE MODE When the engine is at operating temperature this is a CLOSED LOOP mode. During cruising or idle the following inputs are received by the PCM: • Manifold absolute pressure • Crankshaft position (engine speed) • Inlet/Intake air temperature • Engine coolant temperature • Camshaft position • Knock sensor • Throttle position • Exhaust gas oxygen content • A/C control positions • Battery voltage • Vehicle speed The PCM adjusts injector pulse width and controls injector synchronization by turning the individual ground paths to the injectors On and Off. The PCM adjusts engine idle speed and ignition timing. The PCM adjusts the air/fuel ratio according to the oxygen content in the exhaust gas (measured by the upstream and downstream heated oxygen sensor). The PCM monitors for engine misfire. During active misfire and depending on the severity, the PCM either continuously illuminates or flashes the malfunction indicator lamp (Check Engine light on instrument panel). Also, the PCM stores an engine misfire DTC in memory, if 2nd trip with fault. The PCM performs several diagnostic routines. They include: • Oxygen sensor monitor • Downstream heated oxygen sensor diagnostics during open loop operation (except for shorted) • Fuel system monitor • EGR monitor (if equipped) • Purge system monitor • Catalyst efficiency monitor • All inputs monitored for proper voltage range, rationality. • All monitored components (refer to the Emission section for On-Board Diagnostics). FUEL INJECTION RS 14 - 19 FUEL INJECTION (Continued) The PCM compares the upstream and downstream heated oxygen sensor inputs to measure catalytic convertor efficiency. If the catalyst efficiency drops below the minimum acceptable percentage, the PCM stores a diagnostic trouble code in memory, after 2 trips. During certain idle conditions, the PCM may enter a variable idle speed strategy. During variable idle speed strategy the PCM adjusts engine speed based on the following inputs. • A/C sense • Battery voltage • Battery temperature or Calculated Battery Temperature • Engine coolant temperature • Engine run time • Inlet/Intake air temperature • Vehicle mileage ACCELERATION MODE This is a CLOSED LOOP mode. The PCM recognizes an abrupt increase in Throttle Position sensor output voltage or MAP sensor output voltage as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased fuel demand. • Wide Open Throttle-open loop DECELERATION MODE This is a CLOSED LOOP mode. During deceleration the following inputs are received by the PCM: • A/C sense • Battery voltage • Inlet/Intake air temperature • Engine coolant temperature • Crankshaft position (engine speed) • Exhaust gas oxygen content (upstream heated oxygen sensor) • Knock sensor • Manifold absolute pressure • Throttle position sensor • IAC motor (solenoid) control changes in response to MAP sensor feedback The PCM may receive a closed throttle input from the Throttle Position Sensor (TPS) when it senses an abrupt decrease in manifold pressure. This indicates a hard deceleration (Open Loop). In response, the PCM may momentarily turn off the injectors. This helps improve fuel economy, emissions and engine braking. WIDE-OPEN-THROTTLE MODE This is an OPEN LOOP mode. During wide-openthrottle operation, the following inputs are used by the PCM: • Inlet/Intake air temperature • Engine coolant temperature • Engine speed • Knock sensor • Manifold absolute pressure • Throttle position When the PCM senses a wide-open-throttle condition through the Throttle Position Sensor (TPS) it deenergizes the A/C compressor clutch relay. This disables the air conditioning system and disables EGR (if equipped). The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel, based on MAP and RPM. IGNITION SWITCH OFF MODE When the operator turns the ignition switch to the OFF position, the following occurs: • All outputs are turned off, unless 02 Heater Monitor test is being run. Refer to the Emission section for On-Board Diagnostics. • No inputs are monitored except for the heated oxygen sensors. The PCM monitors the heating elements in the oxygen sensors and then shuts down. FUEL CORRECTION or ADAPTIVE MEMORIES DESCRIPTION In Open Loop, the PCM changes pulse width without feedback from the O2 Sensors. Once the engine warms up to approximately 30 to 35° F, the PCM goes into closed loop Short Term Correction and utilizes feedback from the O2 Sensors. Closed loop Long Term Adaptive Memory is maintained above 170° to 190° F unless the PCM senses wide open throttle. At that time the PCM returns to Open Loop operation. OPERATION Short Term The first fuel correction program that begins functioning is the short term fuel correction. This system corrects fuel delivery in direct proportion to the readings from the Upstream O2 Sensor. The PCM monitors the air/fuel ratio by using the input voltage from the O2 Sensor. When the voltage reaches its preset high or low limit, the PCM begins to add or remove fuel until the sensor reaches its switch point. The short term corrections then begin. The PCM makes a series of quick changes in the injector pulse-width until the O2 Sensor reaches its opposite preset limit or switch point. The process then repeats itself in the opposite direction. Short term fuel correction will keep increasing or decreasing injector pulse-width based upon the upstream O2 Sensor input. The maximum range of authority for short term memory is 25% (+/-) of base pulse-width. Short term is violated and is lost when ignition is turned OFF. 14 - 20 FUEL INJECTION RS FUEL INJECTION (Continued) Long Term The second fuel correction program is the long term adaptive memory. In order to maintain correct emission throughout all operating ranges of the engine, a cell structure based on engine rpm and load (MAP) is used. Ther number of cells varies upon the driving conditions. Two cells are used only during idle, based upon TPS and Park/Neutral switch inputs. There may be two other cells used for deceleration, based on TPS, engine rpm, and vehicle speed. The other twelve cells represent a manifold pressure and an rpm range. Six of the cells are high rpm and the other six are low rpm. Each of these cells is a specific MAP voltage range Typical Adaptive Memory Fuel Cells . As the engine enters one of these cells the PCM looks at the amount of short term correction being used. Because the goal is to keep short term at 0 (O2 Sensor switching at 0.5 volt), long term will update in the same direction as short term correction was moving to bring the short term back to 0. Once short term is back at 0, this long term correction factor is stored in memory. The values stored in long term adaptive memory are used for all operating conditions, including open loop and cold starting. However, the updating of the long term memory occurs after the engine has exceeded approximately 170°-190° F, with fuel control in closed loop and two minutes of engine run time. This is done to prevent any transitional temperature or start-up compensations from corrupting long term fuel correction. Long term adaptive memory can change the pulsewidth by as much as 25%, which means it can correct for all of short term. It is possible to have a problem that would drive long term to 25% and short term to another 25% for a total change of 50% away from base pulse-width calculation. TYPICAL ADAPTIVE MEMORY FUEL CELLS Open Throttle Open Throttle Open Throttle Open Throttle Open Throttle Open Throttle Vacuum 20 17 13 9 5 0 Above 1,984 rpm 1 3 5 7 9 Below 1,984 rpm 0 2 4 6 MAP volt = 0 1.4 2.0 2.6 Fuel Correction Diagnostics There are two fuel correction diagnostic routines: • Fuel System Rich • Fuel System Lean A DTC is set and the MIL is illuminated if the PCM detects either of these conditions. This is determined based on total fuel correction, short term times long term. PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) BUS DESCRIPTION The Programmable Communication Interface Multiplex system (PCI Bus) consist of a single wire. The Body Control Module (BCM) acts as a splice to connect each module and the Data Link Connector (DLC) together. Each module is wired in parallel to the data bus through its PCI chip set and uses its ground as the bus reference. The wiring is a minimum 20 gage wire. Idle Decel 11 13 Drive 15 8 10 12 Neutral 14 3.3 3.9 OPERATION Various modules exchange information through a communications port called the PCI Bus. The Powertrain Control Module (PCM) transmits the Malfunction Indicator Lamp (Check Engine) On/Off signal and engine RPM on the PCI Bus. The PCM receives the Air Conditioning select input, transaxle gear position inputs over the PCI Bus. The PCM also receives the air conditioning evaporator temperature signal from the PCI Bus. The following components access or send information on the PCI Bus. • Instrument Panel • Body Control Module • Air Bag System Diagnostic Module • Full ATC Display Head (if equipped) • ABS Module • Transmission Control Module • Powertrain Control Module • Travel Module • SKIM FUEL INJECTION RS 14 - 21 FUEL INJECTION (Continued) SYSTEM DIAGNOSIS OPERATION The PCM can test many of its own input and output circuits. If the PCM senses a fault in a major system, the PCM stores a Diagnostic Trouble Code (DTC) in memory. For (Refer TROL ULE - DTC information see On-Board Diagnostics to 8 - ELECTRICAL/ELECTRONIC CONMODULES/POWERTRAIN CONTROL MODDESCRIPTION) . SPECIFICATIONS TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. MAP SENSOR PLASTIC MANIFOLD 1.7 15 MAP SENSOR ALUMINUM MANIFOLD 3.3 30 POWER STEERING RESERVOIR PLASTIC MANIFOLD 5.7 50 POWER STEERING RESERVOIR ALUMINUM MANIFOLD 11.9 105 THROTTLE CABLE BRACKET PLASTIC MANIFOLD 5.7 50 THROTTLE CABLE BRACKET ALUMINUM MANIFOLD 11.9 105 EGR TUBE PLASTIC MANIFOLD 5.7 50 EGR TUBE ALUMINUM MANIFOLD 11.9 105 THROTTLE BODY BOLTS 2.4L 28 20.65 250 ±50 THROTTLE BODY BOLTS 3.3/3.8L 11.8 8.7 105 ±20 O2 Sensors 27 20 The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpms) to avoid melting the parent material. There are service repair screws avialable for repair. They require a higher torque than the original screws.. 14 - 22 FUEL INJECTION RS FUEL INJECTION (Continued) SPECIAL TOOLS FUEL O2S (Oxygen Sensor) Remover/Installer—C-4907 Pressure Gauge Assembly C–4799–B O2S(Oxygen Sensor) Remover/Installer - 8439 ACCELERATOR PEDAL REMOVAL (1) Hold the throttle body throttle lever in the wide open position. Remove the throttle cable from the throttle body cam (Fig. 1). Fuel Pressure Test Adapter 6539 Spanner Wrench 6856 Fig. 1 THROTTLE CABLE RELEASE Fuel Line Adapter 1/4 (2) From inside the vehicle, hold up the pedal and remove the pedal retainer and throttle cable from the upper end of the pedal lever (Fig. 2). (3) Remove nuts from accelerator pedal attaching studs. Remove assembly from vehicle (Fig. 3). FUEL INJECTION RS 14 - 23 ACCELERATOR PEDAL (Continued) CRANKSHAFT POSITION SENSOR DESCRIPTION The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt (Fig. 4). The 3.3/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing (Fig. 5). The bottom of the sensor is positioned next to the drive plate. Fig. 2 CABLE CLIP Fig. 4 CRANKSHAFT SENSOR 2.4L Fig. 3 ACCELERATOR PEDAL INSTALLATION (1) Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 N·m (105 in. lbs.) torque (Fig. 3). (2) From inside the vehicle, hold up the pedal and install the throttle cable and pedal retainer in the upper end of the pedal lever (Fig. 2). (3) From the engine compartment, hold the throttle body lever in the wide open position and install the throttle cable (Fig. 1). Fig. 5 CRANKSHAFT SENSOR 3.3/3.8L 14 - 24 FUEL INJECTION RS CRANKSHAFT POSITION SENSOR (Continued) OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 6). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots (Fig. 7). Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. Fig. 7 Timing Slots 1 - TORQUE CONVERTER DRIVE PLATE 2 - SLOTS Fig. 6 Crankshaft Position Sensor 1 - CRANKSHAFT POSITION SENSOR The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. REMOVAL (1) (2) (3) (4) (5) Disconnect the negative battery cable. Raise vehicle and support. Disconnect the electrical connector (Fig. 8). Remove crankshaft sensor bolt. Remove the crankshaft sensor. INSTALLATION - 2.4L (1) Install the crankshaft sensor. (2) Install crankshaft sensor bolt and tighten. (3) Connect the electrical connector (Fig. 8). Fig. 8 CRANKSHAFT SENSOR 2.4L (4) Lower vehicle. (5) Connect the negative battery cable. ENGINE SPEED SENSOR DESCRIPTION The PCM receives a signal from the TCM and the transaxle output speed sensor over the bus communication line to indicate vehicle speed on automatic transmission cars. On Manual transmission cars (if equipped) vehicle, a dedicated vehicle speed sensor is connected to the PCM. FUEL INJECTION RS 14 - 25 ENGINE SPEED SENSOR (Continued) OPERATION The Transmission Control Module (TCM) supplies the road speed and distance traveled inputs to the PCM. From these inputs and the throttle position sensor input, the PCM determines when a deceleration condition occurs. pulse width is controlled by the duration of the ground path provided. FUEL INJECTOR DESCRIPTION The injectors are positioned in the intake manifold or cylinder head with the nozzle ends directly above the intake valve port (Fig. 9). Fig. 10 FUEL INJECTOR - TYPICAL 1 - FUEL INJECTOR 2 - NOZZLE 3 - TOP (FUEL ENTRY) REMOVAL REMOVAL - 2.4L The fuel rail must be removed first (Fig. 11). Refer to Fuel Rail Removal in this section. Fig. 9 Fuel Injector Location - Typical 1 - FUEL RAIL 2 - INTAKE MANIFOLD 3 - FUEL INJECTORS OPERATION The fuel injectors are 12 volt electrical solenoids (Fig. 10). 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. The PCM provides battery voltage to each injector through the ASD relay. 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 Fig. 11 FUEL RAIL AND INJECTORS 2.4L 1 - Fuel Injectors 2 - Fuel Rail (1) Disconnect injector wiring connector from injector. (2) Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 12). (3) Rotate injector and pull injector out of fuel rail. The clip will stay on the injector. (4) Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on the injector tip to 14 - 26 FUEL INJECTION RS FUEL INJECTOR (Continued) (1) Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector clip by sliding open end into the top slot of the injector. The edge of the receiver cup will slide into the side slots of clip. (3) Install injector top end into fuel rail receiver cap. Be careful not to damage O-ring during installation (Fig. 13). (4) Repeat steps for remaining injectors. (5) Connect fuel injector wiring. Fig. 12 FUEL INJECTOR AND RAIL TYPICAL 1 - FUEL RAIL ASSEMBLY 2 - FUEL INJECTOR 3 - FUEL RAIL RECEIVER prevent damage. Replace the injector clip if it is damaged. (5) Repeat for remaining injectors. REMOVAL - 3.3/3.8L (1) Disconnect the negative battery cable. (2) Remove the Intake Manifold, (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL) (3) Disconnect injector wiring connector from injector. (4) Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 12). (5) Rotate injector and pull injector out of fuel rail. The clip will stay on the injector. (6) Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on the injector tip to prevent damage. Replace the injector clip if it is damaged. (7) Repeat for remaining injectors. INSTALLATION INSTALLATION - 2.4L The fuel rail must be removed first. Refer to Fuel Injector Rail Removal in this section. Fig. 13 SERVICING FUEL INJECTOR TYPICAL 1 - FUEL INJECTOR 2 - LOCKING SLOT 3 - FUEL RAIL RECEIVER CUP INSTALLATION - 3.3/3.8L (1) Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector clip by sliding open end into the top slot of the injector. The edge of the receiver cup will slide into the side slots of clip (Fig. 12). (3) Install injector top end into fuel rail receiver cap. Be careful not to damage O-ring during installation (Fig. 12). (4) Repeat steps for remaining injectors. (5) Install fuel rail, refer to Fuel Rail in the Fuel Delivery section. (6) Connect fuel injector wiring. (7) Install the Intake Manifold, (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD INSTALLATION) (8) Connect the negative battery cable. FUEL INJECTION RS 14 - 27 FUEL PUMP RELAY DESCRIPTION The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. OPERATION The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Fig. 15 TPS/IAC 3.3/3.8L 1 - Idle Air Control Motor 2 - Throttle Position Sensor OPERATION IDLE AIR CONTROL MOTOR DESCRIPTION The idle air control motor is mounted on the throttle body. The PCM operates the idle air control motor (Fig. 14) or (Fig. 15). The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load, coolant temperature or barometric pressure changes. The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC motor pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning). When engine rpm is above idle speed, the IAC is used for the following functions: • Off-idle dashpot • Deceleration air flow control • A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) Target Idle Fig. 14 TPS/IAC 2.4L 1 - Idle Air Control Motor 2 - Throttle Position Sensor Target idle is determined by the following inputs: • Gear position • ECT Sensor • Battery voltage • Ambient/Battery Temperature Sensor • VSS • TPS • MAP Sensor 14 - 28 FUEL INJECTION RS IDLE AIR CONTROL MOTOR (Continued) REMOVAL When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. Never use lubricants on O-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. (1) Disconnect negative cable from battery. (2) Remove electrical connector from idle air control motor. (3) Remove idle air control motor mounting screws. (4) Remove motor from throttle body. Ensure the O-rings is removed with the motor. INLET AIR TEMPERATURE SENSOR 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 (Fig. 17). INSTALLATION When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. Never use lubricants on O-rings or seals, damage may result. If assembly of component is difficult, a light coat of engine oil may be applied to the O-RINGS ONLY (Fig. 16) to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. Fig. 17 3.3/3.8L IAT SENSOR OPERATION Inlet/Intake Air Temperature Fig. 16 O-RINGS 1 - O-rings (1) The new idle air control motor has a new O-ring installed on it. For 2.4L only, if pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.) (2) Carefully place idle air control motor into throttle body. (3) Install mounting screw(s). Tighten screws to 2 N·m (17 in. lbs.) torque. (4) Connect electrical connector to idle air control motor. (5) Connect negative cable to battery. The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values to use as an intake air temperature sensor and a battery temperature sensor. The Intake Air Temperature (IAT) sensor value is used by the PCM to determine air density. The PCM uses this information to calculate: • Injector pulse width • Adjustment of ignition timing (to prevent spark knock at high intake air temperatures) Battery Temperature The inlet air temperature sensor replaces the intake air temperature sensor and the battery temperature sensor. The PCM uses the information from the inlet air temperature sensor to determine values for the PCM to use as an intake air temperature sensor and a battery temperature sensor. The battery temperature information along with data from monitored line voltage (B+), is used by the PCM to vary the battery charging rate. System volt- FUEL INJECTION RS 14 - 29 INLET AIR TEMPERATURE SENSOR (Continued) age will be higher at colder temperatures and is gradually reduced at warmer temperatures. The battery temperature information is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge, enable LDP). Most OBD II monitors are disabled below 20°F. MAP SENSOR DESCRIPTION The MAP sensor (Fig. 18) or (Fig. 19) mounts to the intake manifold. The sensor is connects electrically to the PCM. Fig. 18 MAP SENSOR - 2.4L Fig. 19 MAP SENSOR - 3.3/3.8L 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 0.5V and full scale is 4.5V. For a pressure swing of 0 — 15 psi the voltage changes 4.0V. 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 you 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 14 - 30 FUEL INJECTION RS MAP SENSOR (Continued) • 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 26 in. of 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 29.92 in Hg. For every 100 feet of altitude barometric pressure drops .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. (2) Install screws and tighten to PLASTIC MANIFOLD 1.7 N·m (15 in. lbs.) ALUMINUM MANIFOLD 3.3 N·m (30 in. lbs.) . (3) Connect the electrical connector to the sensor. Install vacuum hose. (4) Connect the negative battery cable. O2 SENSOR DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 20) or (Fig. 21). REMOVAL REMOVAL - 2.4L (1) Disconnect the negative battery cable. (2) Disconnect electrical connector and vacuum hose from MAP sensor (Fig. 18). (3) Remove two screws holding sensor to the intake manifold. Fig. 20 O2 SENSOR UPSTREAM 1/1 - 2.4L REMOVAL - 3.3/3.8L (1) Disconnect the negative battery cable. (2) Remove vacuum hose and mounting screws from manifold absolute pressure (MAP) sensor (Fig. 19). (3) Disconnect electrical connector from sensor. Remove sensor. INSTALLATION INSTALLATION - 2.4L (1) Install sensor. (2) Install two screws and tighten. (3) Connect the electrical connector and vacuum hose to the MAP sensor (Fig. 18). (4) Connect the negative battery cable. INSTALLATION - 3.3/3.8L (1) Install sensor (Fig. 19). Fig. 21 O2 SENSOR UPSTREAM 1/1 - 3.3/3.8L RS FUEL INJECTION 14 - 31 O2 SENSOR (Continued) The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 22). Fig. 22 O2 SENSOR DOWNSTREAM 1/2 - 2.4/3.3/ 3.8L 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 sensors input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. The PCM uses pulse width modulation to control the ground side of the heater to regulate the temperature on 4 cyl. upstream O2 heater only. All other 4 cyl. and 6 cyl. O2 heaters do not use pulse width modulation. OPERATION UPSTREAM OXYGEN SENSOR A single sensor ground is used for all O2 sensors (2 senors on 4 cyl. vehicles and 4 sensors on 6 cyl. vehicles). 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 voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. 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 0 to 1 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 0.1 volt. When there is a lesser amount of oxygen present (rich airfuel mixture) the sensor produces a voltage as high as 1.0 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 remain in closed loop operation during periods of extended idle. 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 down- 14 - 32 FUEL INJECTION RS O2 SENSOR (Continued) stream 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. Also used to establish the upstream O2 goal voltage (switching point). (7) When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771–64 anti-seize compound or equivalent. REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/3.8L (1) Disconnect the negative battery cable. (2) Raise and support the vehicle. (3) Disconnect the electrical connector (Fig. 24). REMOVAL REMOVAL - UPSTREAM 1/1 - 2.4L (1) Disconnect the negative battery cable. (2) Raise and support the vehicle. (3) Disconnect the electrical connector (Fig. 21). (4) Use a socket such as the Snap-Ont YA8875 or equivalent to remove the sensor (5) When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771–64 anti-seize compound or equivalent. REMOVAL - UPSTREAM 1/1 - 3.3/3.8L (1) Remove battery, refer to the Battery section for more information. (2) Remove the battery tray, refer to the Battery section for more information. (3) Disconnect the speed control vacuum harness from servo. (4) Disconnect the electrical connector from servo. Fig. 24 Downstream Oxygen Sensor (1/2) 1 2 3 4 - OXYGEN SENSOR CONNECTOR CATALYTIC CONVERTER DOWNSTREAM OXYGEN SENSOR ENGINE HARNESS CONNECTOR (4) Use a socket such as the Snap-Ont YA8875 or equivalent to remove the sensor (Fig. 25). (5) When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771–64 anti-seize compound or equivalent. INSTALLATION INSTALLATION - UPSTREAM 1/1 - 2.4L Fig. 23 O2 SENSOR 1/1 (5) Remove the speed control servo and bracket and reposition. (6) Use a socket such as the Snap-Ont YA8875 or equivalent to remove the sensor (Fig. 23). The engines uses two heated oxygen sensors. (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 771- 64 or equivalent. New sensors have compound on the threads and do not require an additional coating. (2) Install sensor and tighten to 27 N·m (20 ft. lbs.) (Fig. 21). (3) Connect the electrical connector for the O2 sensor and install onto bracket. (4) Lower vehicle. (5) Connect the negative battery cable. FUEL INJECTION RS 14 - 33 O2 SENSOR (Continued) NOT add any additional anti-seize compound to the threads of a new oxygen sensor. (1) Install sensor and tighten to 27 N·m (20 ft. lbs.). (2) Connect the electrical connector. (3) Lower vehicle. (4) Install the negative battery cable. THROTTLE BODY DESCRIPTION The throttle body is located on the intake manifold (Fig. 26) or (Fig. 27). Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Fig. 25 DOWNSTREAM 2/1 O2 SENSOR INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L The engines uses two heated oxygen sensors. (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 771- 64 or equivalent. New sensors have compound on the threads and do not require an additional coating. (2) Install sensor and tighten to 27 N·m (20 ft. lbs.). (3) Connect the electrical connector for the O2 sensor and install onto bracket. (4) Connect the electrical connector for the speed control servo. (5) Install the speed control servo and bracket refer to the Speed Control Servo for more information. (6) Connect the speed control vacuum harness to servo. (7) Install the battery tray, refer to the Battery section for more information. (8) Install battery, refer to the Battery section for more information. INSTALLATION DOWNSTREAM 2/1 2.4/3.3/3.8L The O2S is located on the side of the catalytic converter. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO Fig. 26 IAC MOTOR 2.4L 1 - Idle Air Control Motor 2 - Throttle Position Sensor OPERATION Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. 14 - 34 FUEL INJECTION RS THROTTLE BODY (Continued) THROTTLE CONTROL CABLE REMOVAL Fig. 27 IAC MOTOR LOCATION 3.3/3.8L 1 - Idle Air Control Motor 2 - Throttle Position Sensor (1) Working from the engine compartment, hold the throttle body throttle lever in the wide open position. (2) Remove the throttle cable from the throttle body cam. (3) From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft. (4) Remove retainer clip from throttle cable and grommet at dash panel. (5) From the engine compartment, pull the throttle cable and gromment out of the dash panel. (6) Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simultaneously then gently pull the throttle cable from throttle bracket or if it is the slide snap design you have to slide the locking tab out of the hole and then slide the cable assembly out of the bracket. INSTALLATION REMOVAL (1) Disconnect negative cable from battery cable. (2) Remove air inlet to throttle body hose clamp. (3) Remove throttle and the speed control (if equipped) cables from lever and bracket. (4) Disconnect electrical connectors from the idle air control motor and throttle position sensor (TPS) (Fig. 26) or (Fig. 27). (5) Remove throttle body to intake manifold attaching bolts. (6) Remove throttle body and gasket. INSTALLATION (1) Install a new gasket. (2) Install throttle body. (3) Tighten throttle body mounting bolts. The 2.4L to 28.2 N·m (250 ±50 in. lbs.) torque, The 3.3/3.8L to 11.6 N·m (105 ±20 in. lbs.) torque. (4) Connect electrical connectors to the idle air control motor and throttle position sensor (TPS) (Fig. 26) or (Fig. 27). (5) Install air inlet to throttle body hose clamp and tighten. (6) Connect negative cable to battery cable. (1) From the engine compartment, push the housing end fitting and grommet into the dash panel.Install gromment into the dash panel. (2) Install the cable housing (throttle body end) into the cable mounting bracket on the engine. (3) From inside the vehicle, hold up the pedal and install throttle cable and cable retainer in the upper end of the pedal shaft. (4) At the dash panel, install the cable retainer clip between the end of the throttle cable fitting and grommet (5) From the engine compartment, rotate the throttle lever wide open and install the throttle cable. FUEL INJECTION RS 14 - 35 THROTTLE POSITION SENSOR DESCRIPTION The throttle position sensor mounts to the side of the throttle body (Fig. 28) or (Fig. 29).The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). Fig. 29 Throttle Position Sensor—3.3/3.8L Engine 1 - Idle Air Control Motor 2 - Throttle Position Sensor Fig. 28 Throttle Position Sensor—2.4L Engine 1 - Idle Air Control Motor 2 - Throttle Position Sensor OPERATION The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. REMOVAL - 3.3/3.8L (1) Disconnect the negative battery cable. (2) Remove the electrical connector from the Inlet Air Temperature sensor. (3) Remove the air cleaner box lid. Remove hose from throttle body. (4) Disconnect the electrical connector at TPS. (5) Disconnect the electrical connector at IAC. (6) Remove the throttle and speed control cables from throttle body. (7) Remove 3 mounting bolts from throttle body. (8) Remove throttle body. (9) Disconnect the purge vacuum line from the throttle body. (10) Remove TPS from throttle body. INSTALLATION - 3.3/3.8L (1) Install TPS to throttle body. (2) Disconnect the purge vacuum line from the throttle body. (3) Install throttle body. (4) Install 3 mounting bolts from throttle body. Tighten bolts. (5) Install the throttle and speed control cables to throttle body. (6) Connect the electrical connector at TPS. (7) Connect the electrical connector at IAC. (8) Install the air cleaner box lid. Install hose to throttle body. (9) Install the electrical connector to the Inlet Air Temperature sensor. (10) Connect the negative battery cable. FUEL SYSTEM RG 14a - 1 FUEL SYSTEM TABLE OF CONTENTS page FUEL SYSTEM 2.5L TURBO DIESEL DESCRIPTION - DIESEL FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING - HIGH FUEL SYSTEM PRESSURE DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - AIR IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - FUEL SUPPLY RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURES - DRAINING WATER FROM FUEL FILTER . . . . . . . . . . . ...1 ..1 ...1 page STANDARD PROCEDURE - FUEL SYSTEM AIR PURGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 STANDARD PROCEDURES - CLEANING FUEL SYSTEM COMPONENTS . . . . . . . . . . . . 2 SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . . 3 FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 11 ...1 ...2 FUEL SYSTEM 2.5L TURBO DIESEL DESCRIPTION - DIESEL FUEL DELIVERY SYSTEM The fuel system on the 2.5L Common Rail Diesel Engine uses a fuel injection pump and an Electronic Control Module (ECM). The fuel delivery system consists of the: • Accelerator pedal • Air cleaner housing/element • Fuel filter/water separator • Fuel heater • Fuel heater relay • Fuel transfer (lift) pump • Fuel injection pump • Fuel injectors • Fuel tank • Fuel tank filler/vent tube assembly • Fuel tank filler tube cap • Fuel tank module containing the rollover valve and a fuel gauge sending unit (fuel level sensor). • Fuel tubes/lines/hoses • High-pressure fuel injector lines • Low-pressure fuel supply lines • Low-pressure fuel return line • Overflow valve • Quick-connect fittings • Water draining WARNING - HIGH FUEL SYSTEM PRESSURE WARNING:: THE INJECTION PUMP SUPPLIES HIGHPRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH-PRESSURE LINES. FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING. AVOID CONTACT WITH FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE FUEL LINES. DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - AIR IN FUEL SYSTEM Air will enter the fuel system whenever fuel supply lines, separator filters, injection pump, high-pressure lines or injectors are removed or disconnected. Air trapped in the fuel system can result in hard starting, a rough running engine, engine misfire, low power, excessive smoke and fuel knock. After service is performed, air must be bled from the system before starting the engine. Inspect the fuel system from the fuel tank to the injectors for loose connections. Leaking fuel is an indicator of loose connections or defective seals. Air can also enter the fuel system between the fuel tank and the transfer pump. Inspect the fuel tank and fuel lines for damage that might allow air into the system. DIAGNOSIS AND TESTING - FUEL SUPPLY RESTRICTIONS LOW-PRESSURE LINES Fuel supply line restrictions or a defective fuel transfer pump can cause starting problems and prevent engine from accelerating. The starting problems include; low power and/or white fog like exhaust. 14a - 2 FUEL SYSTEM RG FUEL SYSTEM 2.5L TURBO DIESEL (Continued) Test all fuel supply lines for restrictions or blockage. Flush or replace as necessary. Bleed fuel system of air once a fuel supply line has been replaced. Refer to Air Bleed Procedure for procedures. To test for fuel line restrictions, a vacuum restriction test may be performed. HIGH-PRESSURE LINES Restricted (kinked or bent) high-pressure lines can cause starting problems, poor engine performance, engine mis-fire and white smoke from exhaust. Examine all high-pressure lines for any damage. Each radius on each high-pressure line must be smooth and free of any bends or kinks. Replace damaged, restricted or leaking high-pressure fuel lines with correct replacement line. CAUTION: High pressure lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If line is kinked or bent, it must be replaced. Use only recommended lines when replacement of high-pressure fuel line is necessary. STANDARD PROCEDURE STANDARD PROCEDURES - DRAINING WATER FROM FUEL FILTER Refer to Fuel Filter/Water Separator removal/installation for procedures. STANDARD PROCEDURE - FUEL SYSTEM AIR PURGE (1) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL). (2) Remove cap from air purge fitting on the fuel supply line. This fitting is located just behind the alternator (Fig. 1). (3) Attach a hose of about 1 or 2 meters to this fitting using an appropriate connector. (4) Direct the end of the hose into an appropriate fuel container. (5) Turn the ignition to the “ON” position,Do not crank the engine. Keep key on until about 1 liter of fuel has been pumped into the container. (6) While keeping end of hose below fuel level in conatiner, turn the ignition “OFF”. (7) Remove hose from air purge fitting on the fuel supply line and replace cap. (8) Install engine cover (Refer to 9 - ENGINE COVER - INSTALLATION). Fig. 1 AIR PURGE VALVE 1 2 3 4 - AIR PURGE VALVE CAP - AIR PURGE VALVE - ALTERNATOR - ENGINE FRONT COVER STANDARD PROCEDURES - CLEANING FUEL SYSTEM COMPONENTS CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines, fuel rail, and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. FUEL SYSTEM RG FUEL SYSTEM 2.5L TURBO DIESEL (Continued) SPECIFICATIONS - TORQUE 2.5L DIESEL - TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Crankshaft Position Sensor Bolt 10.8 8 96 Boost Pressure / Intake Air Temperature Sensor Bolts 5.4 — 48 Fuel Pump Nuts 27.5 21 — Fuel Line Fittings at Pump 27.5 21 — Fuel Pump Sprocket Nut 88.3 65 — Fuel Injector Retaining Bolts 32.4 24 — High Pressure Fuel Lines 22 17 194 Fuel Rail Bolts 27.5 21 — 14a - 3 14a - 4 FUEL DELIVERY RG FUEL DELIVERY TABLE OF CONTENTS page FUEL RAIL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - FUEL RAIL .............. INSTALLATION - FUEL RAIL . . . . . . . . . . . FUEL FILTER / WATER SEPARATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . FUEL LINES DESCRIPTION DESCRIPTION ................... DESCRIPTION - HIGH PRESSURE FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 .4 .4 .5 .....5 .....5 .....6 .....6 page OPERATION - HIGH PRESSURE FUEL LINES . . 6 DIAGNOSIS AND TESTING - HIGH PRESSURE FUEL LINES . . . . . . . . . . . . . . . . . 6 FUEL TRANSFER PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FUEL INJECTION PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REMOVAL .............................7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 WATER IN FUEL SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FUEL RAIL DESCRIPTION The fuel rail is mounted to the cylinder head cover/ intake manifold (Fig. 1). OPERATION The fuel rail stores the fuel for the injectors at high pressure. At the same time, the pressure oscillations which are generated due to the high-pressure pump delivery and the injection of fuel are dampened by the rail volume. The fuel rail is common to all cylinders, hence it’s name “common rail”. Even when large quantities of fuel are extracted, the fuel rail maintains a constant inner pressure. This ensures that the injection pressure remains constant from the moment the injector opens. REMOVAL - FUEL RAIL (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (3) Disconnect fuel injector high pressure lines. (4) Disconnect fuel rail supply line. (Fig. 2) (5) Disconnect fuel rail return line. (Fig. 2) (6) Disconnect fuel rail high pressure sensor connector. (Fig. 2) (7) Remove engine electrical harness retainers from the fuel rail retaining bolts/studs. (Fig. 2) (8) Remove fuel rail retaining bolts and remove fuel rail (Fig. 2). Fig. 1 ENGINE COMPONENT LOCATIONS 1 - FUEL INJECTOR RETURN LINE 2 - FUEL INJECTOR HIGH PRESSURE LINE 3 - OIL SEPARATOR 4 - FUEL INJECTOR 5 - CAMSHAFT POSITION SENSOR 6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR 7 - EGR SOLENOID 8 - FUEL PRESSURE SENSOR 9 - CYLINDER HEAD COVER/INTAKE MANIFOLD 10 - FUEL RAIL FUEL DELIVERY RG 14a - 5 FUEL RAIL (Continued) FUEL FILTER / WATER SEPARATOR DESCRIPTION The fuel filter/water separator assembly is located under the vehicle in front of the rear axle assembly (Fig. 3). The assembly also includes the fuel heater and Water-In-Fuel (WIF) sensor. Fig. 2 FUEL RAIL COMPONENTS 1 - FUEL INJECTOR RETURN LINE 2 - FUEL INJECTOR HIGH PRESSURE LINE 3 - OIL SEPARATOR 4 - FUEL INJECTOR 5 - CAMSHAFT POSITION SENSOR 6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR 7 - EGR SOLENOID 8 - FUEL PRESSURE SENSOR 9 - CYLINDER HEAD COVER/INTAKE MANIFOLD 10 - FUEL RAIL INSTALLATION - FUEL RAIL (1) Install fuel rail to intake manifold/cylinder head cover (Fig. 2). Torque retaining bolts to 27.5N·m. (2) Install engine electrical harness retainers from the fuel rail retaining bolts/studs. (Fig. 2) (3) Connect fuel rail high pressure sensor electrical connector. (Fig. 2) (4) Connect fuel rail return line. (Fig. 2) (5) Connect fuel rail supply line. (Fig. 2) (6) Connect fuel injector high pressure lines. (Fig. 2) (7) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (8) Connect negative battery cable. Fig. 3 FUEL FILTER/WATER SEPARATOR 1 - LIFT PUMP RETAINING BOLTS 2 - LIFT PUMP 3 - FUEL FILTER/WATER SEPARATOR HOUSING 4 - FUEL HEATER 5 - CHECK BALL 6 - O-RING 7 - FLOW DIVERTER 8 - FUEL FILTER 9 - O-RING 10 - FUEL FILTER BOWL ASSEMBLY OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the canister. 14a - 6 FUEL DELIVERY RG FUEL FILTER / WATER SEPARATOR (Continued) Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation section. A Water-In-Fuel (WIF) sensor is part of the fuel filter cap. Refer to Water-In-Fuel Sensor Description/ Operation. The fuel heater is installed into the filter/separator housing above the fuel filter. Refer to Fuel Heater Description/Operation. FUEL LINES DESCRIPTION DESCRIPTION All fuel lines up to the fuel injection pump are considered low-pressure. This includes the fuel lines from: the fuel tank to the fuel transfer pump, and the fuel transfer pump to the fuel injection pump. The fuel return lines and the fuel drain lines are also considered low-pressure lines. High-pressure lines are used between the fuel injection pump and the fuel injectors. Also refer to High-Pressure Fuel Lines Description/Operation. PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN. DIAGNOSIS AND TESTING - HIGH PRESSURE FUEL LINES High-pressure fuel line leaks can cause starting problems and poor engine performance. WARNING: DUE TO EXTREME FUEL PRESSURES, USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. DO NOT GET YOUR HAND NEAR A SUSPECTED LEAK. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN. Start the engine. Move the cardboard over the high-pressure fuel lines and check for fuel spray onto the cardboard (Fig. 4). If a high-pressure line connection is leaking, bleed the system and tighten the connection. Refer to the Air Bleed Procedure in this group for procedures. Replace damaged, restricted or leaking high-pressure fuel lines with the correct replacement line. DESCRIPTION - HIGH PRESSURE FUEL LINES The high-pressure fuel lines are the 4 lines located between the fuel injection pump and the fuel injectorsctor tubes. All other fuel lines are considered lowpressure lines. OPERATION - HIGH PRESSURE FUEL LINES CAUTION: The high-pressure fuel lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If lines are ever kinked or bent, they must be replaced. Use only the recommended lines when replacement of high-pressure fuel line is necessary. High-pressure fuel lines deliver fuel under extremely high pressure from the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated during the injection process. All high-pressure fuel lines are of the same length and inside diameter. Correct highpressure fuel line usage and installation is critical to smooth engine operation. WARNING: USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION Fig. 4 Typical Test for Leaks with Cardboard 1 - HIGH-PRESSURE LINE 2 - CARDBOARD 3 - FITTING FUEL DELIVERY RG 14a - 7 FUEL LINES (Continued) CAUTION: The high-pressure fuel lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. Only use the recommended lines when replacement of high-pressure fuel line is necessary. FUEL TRANSFER PUMP DESCRIPTION The fuel transfer pump (fuel lift pump) is located under the vehicle in front of the rear axle assembly (Fig. 5). The 12–volt electric vane-type pump is operated and controlled by the Engine Control Module (ECM). OPERATION The purpose of the fuel transfer pump is to supply (transfer) a low-pressure fuel source: from the fuel tank, through the fuel filter/water separator and to the fuel injection pump. Here, the low-pressure is raised to a high-pressure by the fuel injection pump for operation of the high-pressure fuel injectors. The fuel transfer pump is controlled by the Engine Control Module(ECM). The ECM turns the fuel transfer pump on for 30 seconds when the ignition ket is turned “ON”. With the ignition “ON” and fuel tranfer pump running, the low-pressure fuel pressure should be 13-17 psi. FUEL INJECTION PUMP DESCRIPTION A radial-piston pump is used as the high pressure pump for fuel pressure generation (Fig. 6). Fig. 6 FUEL INJECTION PUMP 1 - FUEL INJECTION PUMP 2 - INJECTION PUMP PRESSURE SOLENOID Fig. 5 FUEL TRANSFER(LIFT) PUMP LOCATION 1 - LIFT PUMP RETAINING BOLTS 2 - LIFT PUMP 3 - FUEL FILTER/WATER SEPARATOR HOUSING 4 - FUEL HEATER 5 - CHECK BALL 6 - O-RING 7 - FLOW DIVERTER 8 - FUEL FILTER 9 - O-RING 10 - FUEL FILTER BOWL ASSEMBLY REMOVAL (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE REMOVAL) (3) Remove air cleaner housing assembly. (4) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (5) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). - - 14a - 8 FUEL DELIVERY RG FUEL INJECTION PUMP (Continued) (6) Support engine and remove right engine mount assembly. (7) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (8) Using special tool VM.1055, remove injection pump sprocket retaining nut (Fig. 7). (9) Install feet from VM.1067 in injection pump sprocket as shown (Fig. 8). Fig. 8 VM.1067 FEET INSTALLATION Fig. 7 INJECTION PUMP SPROCKET RETAINING NUT REMOVAL/INSTALLATION 1 2 3 4 - IDLER PULLEY TIMING BELT VM.1055 INJECTION PUMP SPROCKET NOTE: The use of special tool VM.1067 will allow you to remove the injection pump without removing the timing belt from the engine. This will allow you to remove and install the injection pump without altering injection pump timing. 1 2 3 4 5 - OUTER TIMING BELT SEALING SURFACE TIMING BELT TIMING BELT SPROCKET FEET FOR SPECIAL TOOL VM.1067 INNER TIMING BELT COVER (10) Install inner flange of special tool VM.1067 on injection pump sprocket as shown (Fig. 9). Secure flange to feet in injection pump sprocket with allen bolts supplied with tool. (11) Screw injection pump sprocket holding plate assembly into flange of VM.1067 (Fig. 10) Using LHD threaded bolt supplied, secure holding plate assembly to timing belt inner cover. FUEL DELIVERY RG 14a - 9 FUEL INJECTION PUMP (Continued) Fig. 10 INJECTION PUMP/GEAR REMOVAL USING VM.1067 Fig. 9 VM.1067 INSTALLATION 1 2 3 4 - TIMING BELT INJECTION PUMP SPROCKET FLANGE OF VM.1067 INNER TIMING BELT COVER 1 - TIMING BELT 2 - INNER TIMING BELT COVER 3 - INJECTION PUMP SPROCKET HOLDING PLATE ASSEMBLY PART OF VM.1067 4 - INJECTION PUMP SPROCKET INSTALLATION (12) Remove generator (Fig. 11). (Refer to 8 ELECTRICAL/CHARGING/GENERATOR REMOVAL) (13) Disconnect fuel supply and return lines at injection pump (Fig. 11) (14) Disconnect fuel pressure solenoid electrical connector at injection pump (Fig. 11) (15) Remove injection pump retaining nuts. (16) While holding injection pump, tighten bolt in center of injection pump holding plate (Fig. 10).This will push the injection pump out of the injection pump sprocket. (1) Loosen bolt in center of injection pump holding plate and slide injection pump through the accessory bracket into the injection pump sprocket. (2) Install injection pump retaining nuts (Fig. 11). Torque nuts to 27.5N·m. (3) Unscrew injection pump holding plate (part of VM.1067) from inner timing belt cover and remove (Fig. 10). (4) Install injection pump sprocket retaining nut to hold sprocket in place. (5) Remove flange and feet (both part of VM.1067) from injection pump sprocket (Fig. 9) (Fig. 8). 14a - 10 FUEL DELIVERY RG FUEL INJECTION PUMP (Continued) (10) Install outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (11) Install right engine mount assembly. (12) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (13) Install power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (14) Install air cleaner housing assembly. (15) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (16) Connect negative battery cable. WATER IN FUEL SENSOR DESCRIPTION The WIF sensor is located in the bowl assembly of the fuel filter/water separator. Fig. 11 FUEL INJECTION PUMP LOCATION 1 2 3 4 5 - CYLINDER HEAD COVER/INTAKE MANIFOLD - INJECTION PUMP - FUEL PRESSURE SOLENOID - ACCESSORY MOUNTING BRACKET - GENERATOR (6) Using special tool VM.1055 (Fig. 7), torque injection pump sprocket retaining nut to 88.3N·m. (7) Connect fuel pressure solenoid electrical connector (Fig. 11). (8) Connect fuel supply and return lines at injection pump (Fig. 11). (9) Install generator (Fig. 11)(Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION). OPERATION The sensor sends an input to the Engine Control Module (ECM) when it senses water in the fuel filter/ water separator. As the water level in the filter/separator increases, the resistance across the WIF sensor decreases. This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value. Once the value reaches 30 to 40 kilohms, the ECM will activate the water-in-fuel warning lamp through CCD bus circuits. This all takes place when the ignition key is initially put in the ON position. The ECM continues to monitor the input at the end of the intake manifold air heater post-heat cycle. FUEL INJECTION RG 14a - 11 FUEL INJECTION TABLE OF CONTENTS page FUEL INJECTOR DESCRIPTION FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 ACCELERATOR PEDAL POSITION SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL REMOVAL - PEDAL POSITION SENSOR (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL - PEDAL POSITION SENSOR (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION INSTALLATION - PEDAL POSITION SENSOR (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION - PEDAL POSITION SENSOR (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 page BOOST PRESSURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . INTAKE AIR TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT POSITION SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . MASS AIR FLOW (MAF) SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FUEL INJECTOR DESCRIPTION FUEL INJECTOR There are individual fuel injectors for all four cylinders. These fuel injectors are used to spray fuel into the combustion chamber (Fig. 1). OPERATION The injector operation can be subdivided into four operating states with the engine running and the high-pressure pump generating pressure: • Injector closed (with high pressure applied) • Injector opens (start of injection) • Injector opened fully • Injector closes (end of injection) Injector closed (with high pressure applied) With the injector closed (at-rest state), the solenoid valve is not energized and is therefore closed. With the bleed orifice closed, the valve spring forces the armature’s ball onto the bleed-orifice seat. The rail’s high pressure build up in the valve control chamber, and the same pressure is also present in the nozzle’s chamber volume. The rail pressure applied at the control plunger’s end face, together with the force of Fig. 1 FUEL INJECTOR 1 2 3 4 - FUEL INJECTOR NOZZLE FUEL INLET FITTING ELECTRICAL CONNECTION . . . . 14 . . . . 14 . . . . 14 . . . . . . . . . . . . . 15 . 15 . 15 . 15 . . . . 15 . . . . 15 . . . . . . . . . . . . . 16 . 16 . 16 . 16 14a - 12 FUEL INJECTION RG FUEL INJECTOR (Continued) The force exerted by the triggered solenoid now exceeds that of the valve spring and the armature opens the bleed orifice. Almost immediately, the highlevel pick-up current is reduced to the lower holding current required for the electromagnet. This is possible due to the magnetic circuit’s air gap now being smaller. When the bleed orifice opens, fuel can flow from the valve control chamber into the cavity situated above it, and from there via the fuel return to the tank. The bleed orifice prevents complete pressure balance, and the pressure in the valve control chamber sinks as a result. This leads to the pressure in the valve-control chamber being lower than that in the nozzle’s chamber volume which is still at the same pressure level as the rail. The reduced pressure in the valve-control chamber causes a reduction in the force exerted on the control plunger, the nozzle needle open as a result, and injection starts (Fig. 2). Injector opens fully The control plunger reaches its upper stop where it remains supported by a cushion of fuel which is generated by the flow of fuel between the bleed and feed orifices. The injector nozzle has now opened fully, and the fuel is injected into the combustion chamber at a pressure almost equal to that in the fuel rail (Fig. 2). Injector closes (end of injection) Fig. 2 INJECTOR COMPONENTS 1 - INJECTOR CLOSED (AT-REST STATUS) 2 - ELECTRICAL CONNECTION 3 - TRIGGERING ELEMENT (SOLENOID VALVE) 4 - FUEL INLET (HIGH PRESSURE) FROM THE RAIL 5 - VALVE BALL 6 - BLEED ORIFICE 7 - FEED ORIFICE 8 - VALVE CONTROL CHAMBER 9 - VALVE CONTROL PLUNGER 10 - FEED PASSAGE TO THE NOZZLE 11 - NOZZLE NEEDLE the nozzle spring, maintain the nozzle in the closed position against the opening forces applied to its pressure stage (Fig. 2). Injector opens (start of injection) The solenoid valve is energized with the pickup current which serves to ensure that it open quickly. As soon as the solenoid valve is no longer triggered, the valve spring forces the armature downwards and the ball closes the bleed orifice. The armature is a 2–piece design. Here, although the armature plate is guided by a driver shoulder in its downward movement, it can “overspring” with the return spring so that it exerts no downwards-acting forces on the armature and the ball. The closing of the bleed orifice lead to pressure build up in the control chamber via the input from the feed orifice. This pressure is the same as that in the rail and exerts an increased force on the control plunger through its end face. This force, together with that of the spring, now exceeds the force exerted by the chamber volume and the nozzle needle closes. Injection ceases as soon as the nozzle needle comes up against its bottom stop again (Fig. 2). REMOVAL (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE COVER - REMOVAL). (3) Disconnect injector electrical connector. (4) Remove fuel return line from injector (Fig. 3). (5) Remove fuel injector high pressure line (Fig. 3). (6) Remove fuel injector retainer and retaining bolt (Fig. 3). FUEL INJECTION RG 14a - 13 FUEL INJECTOR (Continued) (2) Install fuel injector retainer and bolt (Fig. 3). Torque bolt to 32.4 N·m. (3) Install fuel injector high pressure line (Fig. 3). (4) Install fuel return line to injector (Fig. 3). (5) Connect fuel injector electrical connector. (6) Install engine cover (Refer to 9 - ENGINE COVER - INSTALLATION). (7) Connect negative battery cable. ACCELERATOR PEDAL POSITION SENSOR DESCRIPTION The accelerator pedal position sensor mounts to the accelerator pedal bracket (Fig. 4). Fig. 3 FUEL SYSTEM COMPONENTS 1 - FUEL RAIL RETAINING BOLT 2 - FUEL RAIL RETAINING STUD 3 - FUEL RAIL RETURN LINE 4 - FUEL RAIL 5 - FUEL RAIL SUPPLY LINE 6 - IDLER PULLEY 7 - CRANKSHAFT PULLEY 8 - CRANKSHAFT PULLEY RETAINING BOLTS 9 - BELT TENSIONER RETAINING BOLT 10 - BELT TENSIONER 11 - FUEL INJECTOR RETAINER 12 - FUEL INJECTOR RETURN LINE 13 - FUEL INJECTOR RETAINING BOLT 14 - FUEL INJECTORS 15 - FUEL INJECTOR HIGH PRESSURE SUPPLY LINES (7) Remove fuel injector from cylinder head (Fig. 3). INSTALLATION NOTE: Be sure the copper washer is installed on end of injector before installing in cylinder head. (1) Install fuel injector in cylinder head. Fig. 4 ACCELERATOR PEDAL POSITION SENSOR LOCATION (TYPICAL) 1 - ACCELERATOR CONNECTOR 2 - ACCELERATOR 3 - ACCELERATOR 4 - ACCELERATOR PEDAL POSITION SENSOR ELECTRICAL PEDAL POSITION SENSOR PEDAL PEDAL MOUNTING BRACKET OPERATION The accelerator pedal position sensor contains a potentiometer that is operated by the accelerator pedal. As the accelerator pedal is depressed and released, the sensor provides a variable voltage signal to the engine control module. This voltage signal is directly proportional to accelerator pedal position. When the pedal is fully depressed, the voltage signal is high. 14a - 14 FUEL INJECTION RG ACCELERATOR PEDAL POSITION SENSOR (Continued) REMOVAL REMOVAL - PEDAL POSITION SENSOR (LHD) (1) Disconnect negative battery cable. (2) Disconnect pedal position sensor electrical connector (Fig. 4). (3) Remove 2 pedal position sensor retaining nuts (Fig. 4). (4) Remove pedal position sensor from vehicle. REMOVAL - PEDAL POSITION SENSOR (RHD) (1) Disconnect negative battery cable. (2) Disconnect pedal position sensor electrical connector (Fig. 4). (3) Remove 2 pedal position sensor retaining nuts (Fig. 4). (4) Remove pedal position sensor from vehicle. INSTALLATION INSTALLATION - PEDAL POSITION SENSOR (LHD) (1) Position pedal position sensor in vehicle. (2) Install pedal position sensor retaining nuts (Fig. 4). (3) Connect pedal position sensor electrical connector (Fig. 4). (4) Connect negative battery cable. INSTALLATION - PEDAL POSITION SENSOR (RHD) (1) Position pedal position sensor in vehicle. (2) Install 2 pedal position sensor retaining nuts (Fig. 4). (3) Connect pedal position sensor electrical connector (Fig. 4). (4) Connect negative battery cable. BOOST PRESSURE SENSOR DESCRIPTION The boost pressure/ intake air temperature sensor is mounted to the top of the intake manifold. The sensor allows the ECM to monitor air pressure within the intake manifold. This sensor is also used to monitor the intake air temperature (Fig. 5). Fig. 5 BOOST PRESSURE SENSOR/INTAKE AIR TEMPERATURE SENSOR OPERATION When the intake manifold pressure is low (high vacuum) sensor voltage output is 0.25-1.8 volts at the ECM. When the intake manifold pressure is high due to turbo boost, sensor voltage output is 2.0-4.7 volts. The sensor receives a 5-volts reference from the ECM. Sensor ground is also provides by the ECM. The ECM uses boost pressure combined with intake air temerature to determine the volume of air entering the engine. DIAGNOSIS AND TESTING - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR If the boost pressure sensor fails, the ECM records a DTC into memory and continues to operate the engine in one of the three limp-in modes. When the ECM is operating in this mode, a loss of power will be present, as if the turbocharger was not operating. The best method for diagnosing faults with the boost pressure sensor is with the DRB IIIt scan tool. Refer to the Diesel Powertrain Diagnostic Manual for more information. Refer to On-Board Diagnostics in Emissions Control System for a list of Diagnostic Trouble Codes (DTC’s) for certain fuel system components. FUEL INJECTION RG INTAKE AIR TEMPERATURE SENSOR DESCRIPTION The boost pressure sensor/intake air temperature sensor is located in the top of the intake manifold (Fig. 6). The intake air temperature sensor is used to measure the intake air temperature. The intake air temperture sensor is a dual purpose sensor. It is also used as a boost pressure sensor. 14a - 15 (3) Disconnect intake air temperature electrical connector. (4) Remove intake air temperature sensor retaining screws and sensor (Fig. 6). INSTALLATION (1) Install intake air temperature sensor and retaining bolts (Fig. 6). Torque to 5.4 N·m. (2) Connect intake air temperature sensor. (3) Install engine cover and retaining bolts (Refer to 9 - ENGINE COVER - INSTALLATION). CRANKSHAFT POSITION SENSOR DESCRIPTION The crankshaft position sensor is mounted in the right rear of the engine block below the turbocharger (Fig. 7). This sensor is used to detect engine speed. Fig. 6 BOOST PRESSURE SENSOR/INTAKE AIR TEMPERATURE SENSOR LOCATION 1 2 3 4 - FUEL RAIL FUEL PRESSURE SENSOR INTAKE AIR TEMPERATURE/BOOST PRESSURE SENSOR CYLINDER HEAD COVER/INTAKE MANIFOLD Fig. 7 CRANKSHAFT POSITION SENSOR 1 - CRANKSHAFT POSITION SENSOR 2 - CRANKSHAFT POSITION SENSOR ELECTRICAL CONNECTOR OPERATION The intake air temperature sensor is a negative temperature coefficient (NTC) thermistor (resistance varies inversly with temperature). This means at cold air temperature its resistance is high, sothe voltage signal will be high. As intake air temperature increases, sensor resistance decreases and the signal voltage will be low. This allows the sensor to provide an analog voltage signal (0.2-4.8 volts) to the ECM. REMOVAL (1) Disconnect negative battery cable. (2) Remove engine cover retaining bolts and cover(Refer to 9 - ENGINE COVER - REMOVAL). OPERATION The crankshaft position sensor is a magnetic pickup type sensor that generates an ac signal. The sensor contains a permanent magent and a coil of wire. The sensor generates an ac signal each time a notch in the reluctor wheel on the crankshaft passes across the permanent magnet. The ECM calculates engine speed based on the frequency of the ac signal. The ECM supplies the sensor ground. 14a - 16 FUEL INJECTION MASS AIR FLOW (MAF) SENSOR DESCRIPTION The Mass Air Flow (MAF) Sensor is mounted inline in the air intake between the air filter and the turbocharger (Fig. 8). RG by the ECM. The MAF sensor signal is provided by the ECM. REMOVAL (1) (2) (Fig. (3) (4) Disconnect negative battery cable. Disconnect MAF sensor electrical connector 9). Loosen MAF sensor retaining clamps (Fig. 9). Remove MAF sensor from airduct (Fig. 9). Fig. 8 MASS AIR FLOW (MAF) SENSOR OPERATION Fig. 9 MASS AIR FLOW (MAF) SENSOR LOCATION The ECM uses the mass air flow (MAF) sensor to measure air density. The MAF sensor contains a ceramic element. A signal voltage is provided to the element. As engine speed increases, airflow across the ceramic element increases. Changes in air flow and air density cause the temperature of the ceramic element to fluxuate. The ceramic element changes resistance respectively to changes in temperature. The change in resistance varies the signal voltage output to the ECM. The diesel power relay supplies battery power the to MAF sensor. Ground is provided 1 2 3 4 - MAF SENSOR ELECTRICAL CONNECTOR - RETAINING CLAMPS - MASS AIR FLOW (MAF) SENSOR - AIR CLEANER HOUSING INSTALLATION (1) (2) (3) 9). (4) Install MAF sensor in airduct (Fig. 9). Tighten retaining clamps (Fig. 9). Connect MAF sensor electrical connector (Fig. Connect negative battery cable. DIFFERENTIAL & DRIVELINE RS 3-1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page HALF SHAFT - FRONT . . . . . . . . . . . . . . . . . . . . . 1 HALF SHAFT - REAR . . . . . . . . . . . . . . . . . . . . . 14 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 22 REAR DRIVELINE MODULE . . . . . . . . . . . . . . . . 24 HALF SHAFT - FRONT TABLE OF CONTENTS page HALF SHAFT - FRONT DESCRIPTION . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - HALF SHAFT REMOVAL ....................... INSTALLATION . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS - HALF SHAFT - FRONT CV BOOT - INNER REMOVAL ....................... .. . .. .. . . . . . . . . . . . . . . . .1 .1 .2 .4 .6 page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CV BOOT - OUTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OUTER CV JOINT BEARING SHIELD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 ......6 HALF SHAFT - FRONT DESCRIPTION All vehicles use an unequal length half shaft system (Fig. 1). The left half shaft uses a tuned rubber damper weight. When replacing the left half shaft, be sure the replacement half shaft has the same damper weight as the original. All half shaft assemblies use the same type of inner and outer joints. The inner joint of both half shaft assemblies is a tripod joint, and the outer joint of both half shaft assemblies is a Rzeppa joint. Both tripod joints and Rzeppa joints are true constant velocity (CV) joint assemblies. The inner tripod joint allows for the changes in half shaft length through the jounce and rebound travel of the front suspension. On vehicles equipped with ABS brakes, the outer CV joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both half shafts is splined into the transaxle side gears. The inner tripod joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of the tripod joint. The outer CV joint has a stub shaft that is splined into the wheel hub and retained by a steel hub nut. DIAGNOSIS AND TESTING - HALF SHAFT VEHICLE INSPECTION (1) Check for grease in the vicinity of the inboard tripod joint and outboard CV joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: • Damaged outer CV or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. • Noise may also be caused by another component of the vehicle coming in contact with the half shafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: • A torn seal boot on the inner or outer joint of the half shaft assembly. 3-2 HALF SHAFT - FRONT RS HALF SHAFT - FRONT (Continued) Fig. 1 Unequal Length Half Shaft System 1 2 3 4 5 6 7 - STUB AXLE OUTER C/V JOINT OUTER C/V JOINT BOOT TUNED RUBBER DAMPER WEIGHT INTERCONNECTING SHAFT OUTER C/V JOINT BOOT STUB AXLE • A loose or missing clamp on the inner or outer joint of the half shaft assembly. • A damaged or worn half shaft CV joint. 8 - OUTER C/V JOINT 9 - RIGHT HALFSHAFT 10 - INNER TRIPOD JOINT BOOT 11 - INNER TRIPOD JOINT 12 - INNER TRIPOD JOINT 13 - INNER TRIPOD JOINT BOOT 14 - INTERCONNECTING SHAFT LEFT HALFSHAFT (2) Remove the cotter pin and nut lock (Fig. 2) from the end of the half shaft. SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: • A worn or damaged half shaft inner tripod joint. • A sticking tripod joint spider assembly (inner tripod joint only). • Improper wheel alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE) VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: • Foreign material (mud, etc.) packed on the backside of the wheel(s). • Out of balance tires or wheels. (Refer to 22 TIRES/WHEELS - STANDARD PROCEDURE) • Improper tire and/or wheel runout. (Refer to 22 TIRES/WHEELS - DIAGNOSIS AND TESTING) REMOVAL (1) Raise vehicle. Fig. 2 Half Shaft Retaining Nut 1 2 3 4 - HUB/BEARING NUT LOCK COTTER PIN STUB AXLE HALF SHAFT - FRONT RS 3-3 HALF SHAFT - FRONT (Continued) (3) Remove the wheel and tire assembly from the vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL) (4) Remove the wave washer (Fig. 3) from the end of the half shaft. (7) Remove the disc brake caliper assembly from the steering knuckle. Caliper assembly is removed by first rotating top of caliper assembly away from steering knuckle and then removing bottom of assembly out from under machined abutment on steering knuckle. (8) Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly (Fig. 5). Do not allow the brake caliper assembly to hang by the brake flex hose. Fig. 3 Wave Washer 1 - HUB/BEARING ASSEMBLY 2 - WAVE WASHER 3 - STUB AXLE (5) With the vehicle’s brakes applied to keep hub from turning, loosen and remove the half shaft nut. (6) Remove the two front disc brake caliper adapter to steering knuckle attaching bolts (Fig. 4). Fig. 5 Properly Supported Disc Brake Caliper Typical 1 2 3 4 5 - STEERING KNUCKLE BRAKE FLEX HOSE CALIPER ASSEMBLY WIRE HANGER STRUT ASSEMBLY (9) Remove the brake rotor from the hub and bearing assembly. (10) Remove the steering knuckle-to-strut attachment bolts (Fig. 6) from the steering knuckle. (11) Pull the steering knuckle from the strut clevis bracket. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow half shaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of half shaft must be supported. Fig. 4 Front Brake Mounting 1 2 3 4 5 6 7 - BRAKE ROTOR - HUB AND BEARING - STEERING KNUCKLE - ADAPTER MOUNTING BOLTS - BRAKE CALIPER - ADAPTER - CLIP (12) Pull steering knuckle assembly down and away from the outer C/V joint of the half shaft assembly while pulling the joint out of the hub bearing. 3-4 HALF SHAFT - FRONT RS HALF SHAFT - FRONT (Continued) Fig. 6 Strut To Steering Knuckle Attaching Bolts 1 - STRUT CLEVIS BRACKET 2 - NUTS AND BOLTS 3 - STEERING KNUCKLE (13) Support the outer end of the half shaft assembly. Insert a pry bar between inner tripod joint and transaxle case (Fig. 7). Pry against inner tripod joint, until tripod joint retaining snap-ring is disengaged from transaxle side gear. Fig. 7 Disengaging Inner Tripod Joint From Transaxle 1 - INNER TRIPOD JOINT 2 - TRANSAXLE CASE 3 - PRY BAR (14) Hold inner tripod joint and interconnecting shaft of half shaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal (Fig. 8). When removing tripod joint, do not let spline or snap-ring drag across sealing lip of the transaxle to tripod joint oil seal. Fig. 8 Tripod Joint Removal from Transaxle 1 2 3 4 5 6 - INNER TRIPOD JOINT TRANSAXLE SPLINE OIL SEAL SNAP-RING INTERCONNECTING SHAFT INSTALLATION (1) Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. (2) Holding half shaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand (Fig. 8). (3) Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap-ring is engaged with transaxle side gear. Test that snap-ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap-ring is fully engaged with side gear, tripod joint will not be removable by hand. (4) Clean all debris and moisture out of steering knuckle, in the area were outer CV joint will be installed into steering knuckle. (5) Ensure that front of outer CV joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer CV joint into hub and bearing assembly (Fig. 9). (6) Slide half shaft back into front hub and bearing assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckle. HALF SHAFT - FRONT RS 3-5 HALF SHAFT - FRONT (Continued) Fig. 9 Outer CV Joint Inspection 1 - OUTER C/V JOINT 2 - THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO STEERING KNUCKLE. CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket (Fig. 10). (9) Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper assembly under abutment on steering knuckle, and then rotating top of caliper against top abutment. (10) Install disc brake caliper adapter to steering knuckle attaching bolts (Fig. 4). Tighten the disc brake caliper adapter attaching bolts to a torque of 169 N·m (125 ft. lbs.). (11) Clean all foreign matter from the threads of the outer CV joint. Install the washer and half shaft to hub/bearing assembly nut on half shaft and securely tighten nut. (12) Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (13) Lower vehicle. (14) With the vehicle’s brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 N·m (180 ft. lbs.) (Fig. 11). Fig. 11 Torquing Front Half Shaft To Hub Nut 1 - TORQUE WRENCH Fig. 10 Correctly Installed Eccentric Attaching Bolt 1 2 3 4 - STEERING KNUCKLE FLANGED BOLT IN TOP HOLE CAM BOLT IN BOTTOM HOLE STRUT CLEVIS BRACKET (7) Install steering knuckle in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both bolts to a torque of 81 N·m (60 ft. lbs.) plus an additional 1/4 turn. (8) Install braking disc on hub and bearing assembly. (15) Install the spring wave washer on the end of the half shaft. (16) Install the hub nut lock, and a new cotter pin (Fig. 2). Wrap cotter pin prongs tightly around the hub nut lock as shown in (Fig. 2). (17) Check for correct fluid level in transaxle assembly. (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE/FLUID - STANDARD PROCEDURE) 3-6 HALF SHAFT - FRONT RS HALF SHAFT - FRONT (Continued) SPECIFICATIONS - HALF SHAFT - FRONT TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolts, Caliper Adapter to Knuckle 169 125 - Nut, Hub 244 180 - Nuts, Front Wheel Lug 135 100 - Nut, Tie Rod End to Knuckle 75 55 - Nut, Strut Clevis to Knuckle 81 +90° 60 +90° - CV BOOT - INNER REMOVAL (1) Remove the half shaft requiring boot replacement from the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) (2) Remove large boot clamp which retains inner tripod joint sealing boot to tripod joint housing and discard. (3) Remove small clamp which retains inner tripod joint sealing boot to interconnecting shaft and discard. (4) Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. (6) Remove snap-ring which retains spider assembly to interconnecting shaft (Fig. 13). Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft. (7) Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift (Fig. 14). CAUTION: When removing the tripod joint housing from the spider assembly, hold the bearings in place on the spider trunions to prevent the bearings from falling away. (5) Slide the tripod joint housing off the spider assembly and the interconnecting shaft (Fig. 12). Fig. 13 Spider Assembly Retaining Snap-Ring 1 - INTERCONNECTING SHAFT 2 - SPIDER ASSEMBLY 3 - RETAINING SNAP-RING Fig. 12 Spider Assembly Removal from Tripod Joint Housing 1 - TRIPOD JOINT HOUSING 2 - SPIDER ASSEMBLY 3 - SEALING BOOT (8) Slide sealing boot off interconnecting shaft. (9) 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 half shaft assembly will require replacement. Component parts of these half shaft assemblies are not serviceable. INSTALLATION (1) Slide inner CV joint seal boot retaining clamp, onto the interconnecting shaft. Then, slide the replacement inner CV joint sealing boot onto the interconnecting shaft. Inner CV joint seal boot HALF SHAFT - FRONT RS 3-7 CV BOOT - INNER (Continued) (2) Install spider assembly onto interconnecting shaft (Fig. 16). Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap-ring. If the spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift (Fig. 17). Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. Fig. 14 Spider Assembly Removal from Interconnecting Shaft 1 - SPIDER ASSEMBLY 2 - DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN REMOVING SPIDER ASSEMBLY 3 - BRASS DRIFT 4 - INTERCONNECTING SHAFT MUST be positioned on interconnecting shaft so the raised bead on the inside of the small diameter end of the seal boot is in mating groove on interconnecting shaft (Fig. 15). Fig. 16 Spider Assembly Installation on Interconnecting Shaft 1 - SPIDER ASSEMBLY 2 - INTERCONNECTING SHAFT Fig. 15 Sealing Boot Installation on Interconnecting Shaft 1 2 3 4 - SEALING BOOT RAISED BEAD IN THIS AREA OF SEALING BOOT GROOVE INTERCONNECTING SHAFT Fig. 17 Installing Spider Assembly on Interconnecting Shaft 1 - DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER ASSEMBLY 2 - SPIDER ASSEMBLY 3 - INTERCONNECTING SHAFT 4 - BRASS DRIFT 3-8 HALF SHAFT - FRONT RS CV BOOT - INNER (Continued) (3) Install the spider assembly to interconnecting shaft retaining snap-ring into groove on end of interconnecting shaft (Fig. 18). Be sure the snap-ring is fully seated into groove on interconnecting shaft. (6) Install inner CV joint seal boot to interconnecting shaft clamp evenly on sealing boot. (7) Place crimping tool C-4975-A over bridge of clamp (Fig. 20). (8) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 21). Fig. 18 Spider Assembly Retaining Snap-Ring Installed 1 - INTERCONNECTING SHAFT 2 - SPIDER ASSEMBLY 3 - RETAINING SNAP-RING (4) 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. (5) Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft (Fig. 19). Fig. 20 Crimping Tool Installed on Sealing Boot Clamp - Typical 1 2 3 4 - SPECIAL TOOL C-4975-A INTERCONNECTING SHAFT CLAMP SEALING BOOT Fig. 21 Sealing Boot Retaining Clamp Installed Typical Fig. 19 Installing Tripod Housing on Spider Assembly 1 - TRIPOD JOINT HOUSING 2 - SPIDER ASSEMBLY 3 - SEALING BOOT 1 - CLAMP 2 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT HALF SHAFT - FRONT RS 3-9 CV BOOT - INNER (Continued) CAUTION: Seal boot must not be dimpled, stretched or out of shape in any way. If seal boot is NOT shaped correctly, equalize pressure in seal and shape it by hand. (9) Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. (10) Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recess’s of the tripod housing. CAUTION: The following positioning procedure determines the correct air pressure inside the inner CV joint assembly prior to clamping the sealing boot to inner CV joint housing. If this procedure is not done prior to clamping sealing boot to CV joint housing sealing boot durability can be adversely affected. joint housing. Remove the trim stick from between the sealing boot insert and the CV joint housing. This procedure will equalize the air pressure in the CV joint, preventing premature sealing boot failure. (13) Clamp CV joint sealing boot to CV joint, using required procedure for type of boot clamp application. CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp, use the following procedure to install the retaining clamp. (1) Place crimping tool C-4975-A over bridge of clamp (Fig. 23). (2) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 24). CAUTION: When venting the inner CV joint assembly, use care so that the inner CV sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot can not be used. (11) Insert a trim stick between the CV joint housing and the sealing boot insert to vent inner CV joint assembly (Fig. 22). 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. Fig. 23 Crimping Tool Installed on Sealing Boot Clamp 1 2 3 4 - CLAMP TRIPOD JOINT HOUSING SPECIAL TOOL C-4975-A SEALING BOOT Fig. 22 Trim Stick Inserted for Venting CV Joint 1 2 3 4 - INNER CV JOINT SEALING BOOT SEALING BOOT CLAMP INNER CV JOINT HOUSING TRIM STICK (12) With trim stick inserted between sealing boot insert and the CV joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod Fig. 24 Sealing Boot Retaining Clamp Installed 1 - CLAMP 2 - TRIPOD HOUSING 3 - SPECIAL TOOL C-4975-A 4 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT 3 - 10 HALF SHAFT - FRONT RS CV BOOT - INNER (Continued) LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp, use the following procedure to install the retaining clamp. (1) Place prongs of clamp locking tool in the holes of the clamp (Fig. 25). (2) Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (Fig. 26). CV BOOT - OUTER REMOVAL (1) Remove half shaft assembly requiring boot replacement from vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) (2) Remove large boot clamp retaining CV joint sealing boot to CV joint housing (Fig. 27) and discard. (3) Remove small clamp that retains outer CV joint sealing boot to interconnecting shaft and discard. (4) Remove sealing boot from outer CV joint housing and slide it down interconnecting shaft. Fig. 25 Clamping Tool Installed on Sealing Boot Clamp 1 - CLAMP 2 - TOOL YA3050, OR EQUIVALENT 3 - SEALING BOOT Fig. 27 Outer CV Joint Seal Boot Clamps 1 2 3 4 5 Fig. 26 Sealing Boot Clamp Correctly Installed 1 - INNER TRIPOD JOINT HOUSING 2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP 3 - SEALING BOOT (14) Install the half shaft back into the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) - SMALL CLAMP SEALING BOOT OUTER C/V JOINT HOUSING LARGE CLAMP INTERCONNECTING SHAFT (5) Wipe away grease to expose outer CV joint to interconnecting shaft retaining ring. (6) Spread ears apart on CV joint assembly to interconnecting shaft retaining ring (Fig. 28). (7) Slide outer CV joint assembly off end of interconnecting shaft. (8) Slide sealing boot off interconnecting shaft. (9) 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 half shaft assembly will require replacement. Component parts of these half shaft assemblies are not serviceable. INSTALLATION (1) Slide the new small diameter seal boot retaining clamp onto the interconnecting shaft. Then slide HALF SHAFT - FRONT RS 3 - 11 CV BOOT - OUTER (Continued) (3) 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) Install outer CV joint seal boot retaining clamp, onto interconnecting shaft. Install replacement outer CV joint sealing boot onto interconnecting shaft. Outer CV joint seal boot MUST be positioned on interconnecting shaft, so that only the thinnest (sight) groove on interconnecting shaft is visible (Fig. 30). Fig. 28 Outer CV Joint Removal From Interconnecting Shaft 1 - SPREAD RETAINING RING EARS AND PULL JOINT OFF SHAFT 2 - RETAINING SNAP RING 3 - RETAINING RING 4 - OUTER C/V JOINT ASSEMBLY 5 - INTERCONNECTING SHAFT the replacement outer CV joint assembly sealing boot onto the interconnecting shaft. (2) Install the outer CV joint assembly onto the interconnecting shaft. Joint is installed on interconnecting shaft, by pushing interconnecting shaft into outer CV joint, until retaining ring is seated in groove on interconnecting shaft (Fig. 29). Verify that the retaining ring is fully seated into groove on interconnecting shaft. Fig. 29 Outer CV Joint Installed On Interconnecting Shaft 1 - INTERCONNECTING SHAFT 2 - RETAINING SNAP RING 3 - OUTER C/V JOINT ASSEMBLY Fig. 30 Seal Boot Correctly Positioned On Interconnecting Shaft 1 2 3 4 - SEALING BOOT INTERCONNECTING SHAFT THINNEST GROOVE INTERCONNECTING SHAFT BOOT CLAMP (5) Place crimping tool C- 4975-A over bridge of clamp (Fig. 31). Fig. 31 Crimping Tool Installed on Sealing Boot Clamp 1 2 3 4 - SPECIAL TOOL C-4975-A INTERCONNECTING SHAFT CLAMP SEALING BOOT 3 - 12 HALF SHAFT - FRONT RS CV BOOT - OUTER (Continued) (6) Tighten nut on crimping tool C- 4975-A until jaws on tool are closed completely together, face to face (Fig. 32). Fig. 33 Crimping Tool Installed on Sealing Boot Clamp - Typical Fig. 32 Sealing Boot Retaining Clamp Installed 1 - CLAMP 2 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT 1 2 3 4 - CLAMP TRIPOD JOINT HOUSING SPECIAL TOOL C-4975-A SEALING BOOT CAUTION: Seal boot must not be dimpled, stretched, or out-of-shape in any way. If seal boot is NOT shaped correctly, equalize pressure in seal and shape it by hand. (7) Position outer CV joint sealing boot into its retaining groove on outer CV joint housing. (8) Install sealing boot to outer CV joint retaining clamp evenly on sealing boot. (9) Place crimping tool C- 4975-A over bridge of clamp (Fig. 33). (10) Tighten nut on crimping tool C- 4975-A until jaws on tool are closed completely together, face to face (Fig. 34). (11) Install the half shaft requiring boot replacement back on the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT INSTALLATION) Fig. 34 Sealing Boot Retaining Clamp Installed Typical 1 - CLAMP 2 - TRIPOD HOUSING 3 - SPECIAL TOOL C-4975-A 4 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT HALF SHAFT - FRONT RS 3 - 13 OUTER CV JOINT BEARING SHIELD REMOVAL (1) Clamp half shaft in a vise by the interconnecting shaft. (2) Using a drift (Fig. 35) tap around the entire edge of the bearing shield until it is removed from the outer CV joint. Fig. 36 Special Tools for Installing Bearing Shield 1 2 3 4 - SPECIAL TOOL C-4698–2 SPECIAL TOOL C-4698–1 BEARING SHIELD OUTER C/V JOINT Fig. 35 Removing Bearing Shield from Outer CV Joint 1 - DRIFT 2 - OUTER C/V JOINT 3 - BEARING SHIELD INSTALLATION (1) Install bearing shield by hand on outer CV Joint so that it is installed squarely on the CV joint. (2) Position installer, Special Tool C-4698-2, and handle, Special Tool C-4698-1, on face of bearing shield (Fig. 36). CAUTION: If bearing shield is not installed flush against the face of the outer CV joint, interference with steering knuckle will occur when driveshaft is installed. (3) Using a hammer, drive the bearing shield on the outer CV joint until it is flush against the front of the outer CV joint (Fig. 37). Fig. 37 Correctly Installed Bearing Shield 1 - HAMMER 2 - SPECIAL TOOL C-4698–2 3 - BEARING SHIELD 4 - BEARING SEAL MUST BE FLUSH WITH FRONT OF OUTER C/V JOINT 5 - SPECIAL TOOL C-4698–1 3 - 14 HALF SHAFT - REAR RS HALF SHAFT - REAR TABLE OF CONTENTS page HALF SHAFT - REAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - HALF SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . . . . . . . 14 . 14 . 15 . 15 HALF SHAFT - REAR DESCRIPTION The inner and outer joints of both half shaft assemblies are tripod joints. The tripod joints are true constant velocity (CV) joint assemblies, which allow for the changes in half shaft length through the jounce and rebound travel of the rear suspension. On vehicles equipped with ABS brakes, the outer CV joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both half shafts is bolted rear differential assembly’s output flanges. The outer CV joint has a stub shaft that is splined into the wheel hub and retained by a steel hub nut. DIAGNOSIS AND TESTING - HALF SHAFT VEHICLE INSPECTION (1) Check for grease in the vicinity of the inboard tripod joint and outboard CV joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: • Damaged outer CV or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. page SPECIFICATIONS - HALF SHAFT - FRONT . . . 16 CV BOOT - INNER/OUTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 • Noise may also be caused by another component of the vehicle coming in contact with the half shafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: • A torn seal boot on the inner or outer joint of the half shaft assembly. • A loose or missing clamp on the inner or outer joint of the half shaft assembly. • A damaged or worn half shaft CV joint. SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: • A worn or damaged half shaft inner tripod joint. • A sticking tripod joint spider assembly (inner tripod joint only). • Improper wheel alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE) VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: • Foreign material (mud, etc.) packed on the backside of the wheel(s). • Out of balance tires or wheels. (Refer to 22 TIRES/WHEELS - STANDARD PROCEDURE) • Improper tire and/or wheel runout. (Refer to 22 TIRES/WHEELS - DIAGNOSIS AND TESTING) HALF SHAFT - REAR RS 3 - 15 HALF SHAFT - REAR (Continued) REMOVAL (1) Lift vehicle on hoist so that the wheels hang freely. (2) Remove rear wheel. (3) Remove cotter pin, nut lock, and wave washer (Fig. 1). Fig. 1 Cotter Pin, Nut Lock, And Wave Washer 1 2 3 4 - HUB NUT NUT LOCK COTTER PIN SPRING WASHER (4) Remove hub nut and washer. CAUTION: The half shaft outer CV joint, when installed, acts as a bolt and secures the hub/bearing assembly. If the vehicle is to be supported or moved on its wheels, install and torque a bolt through the hub. This will ensure that the hub/bearing assembly cannot loosen. (6) The half shaft is spring loaded. Compress inner half shaft joint slightly and pull downward to clear rear differential output flange. Then pull half shaft assembly outward to remove (Fig. 3). Fig. 3 Half Shaft Removal 1 - BRAKE BACKING PLATE 2 - HALF SHAFT INSTALLATION (1) Install the outer CV joint stub shaft through the hub bearing (Fig. 4). (2) The half shaft is spring loaded. Compress inner half shaft joint slightly and push upward until the inner CV joint flange engages the rear differential output flange. (5) Remove inner half shaft retaining bolts (Fig. 2). Fig. 4 Half Shaft Installation 1 - BRAKE BACKING PLATE 2 - HALF SHAFT Fig. 2 Inner Half Shaft Bolts 1 - SHAFT 2 - FLANGE (3) Install the inner half shaft retaining bolts (Fig. 5). Torque the bolts to 61 N·m (45 ft.lbs.). 3 - 16 HALF SHAFT - REAR RS HALF SHAFT - REAR (Continued) Fig. 6 Cotter Pin, Nut Lock, And Wave Washer Fig. 5 Inner Half Shaft Bolts 1 - SHAFT 2 - FLANGE (4) Install the half shaft washer and hub nut. Torque the hub nut to 244 N·m (180 ft.lbs.). (5) Install the wave washer, nut lock, and a new cotter pin (Fig. 6). Be sure to wrap the cotter pin prongs tightly around the hub nut lock. 1 2 3 4 - HUB NUT NUT LOCK COTTER PIN SPRING WASHER (6) Install rear wheel. Torque the lug nuts to 135 N·m (100 ft.lbs.). SPECIFICATIONS - HALF SHAFT - FRONT TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Nut, Hub 244 180 - Nuts, Rear Wheel Lug 135 100 - Bolt, Half Shaft to Output Flange 61 45 - HALF SHAFT - REAR RS CV BOOT - INNER/OUTER 3 - 17 (4) Pull the boot back from the CV joint (Fig. 9). REMOVAL (1) Remove half shaft from vehicle. (Refer to 3 DIFFERENTIAL & DRIVELINE/HALF SHAFT REMOVAL) (2) Clamp the half shaft into a suitable vise with protective jaws clamped onto the interconnecting shaft (Fig. 7). Fig. 9 Pull Back Boot Fig. 7 Clamp Shaft In Soft Jawed Vice 1 - HALF SHAFT BOOT 2 - HALF SHAFT 3 - VISE 1 - HALF SHAFT BOOT 2 - HALF SHAFT JOINT (5) Remove the CV housing from the interconnecting shaft and tripod assembly (Fig. 10). (3) Remove the large and small diameter retaining clamps holding the CV boot to the CV joint and the interconnecting shaft (Fig. 8). Fig. 8 Remove Boot Clamps 1 - HALF SHAFT BOOT 2 - CLAMP Fig. 10 Remove CV Housing 1 - HALF SHAFT JOINT HOUSING 2 - BOOT 3 - 18 HALF SHAFT - REAR RS CV BOOT - INNER/OUTER (Continued) (6) Remove the snap-ring holding the tripod assembly onto the interconnecting shaft (Fig. 11). Fig. 11 Remove Snap-Ring 1 2 3 4 - SNAP RING HALF SHAFT BOOT TRIPOD ASSEMBLY SNAP RING PLIERS (7) Remove the tripod assembly from the interconnecting shaft (Fig. 12). (8) Remove the CV boot from the interconnecting shaft (Fig. 13). Fig. 13 Remove Boot 1 - HALF SHAFT BOOT INSTALLATION (1) Clean the interconnecting shaft and inner CV joint of any residual grease and dirt. (2) Slide the new small diameter retaining clamp onto the interconnecting shaft. (3) Install the CV boot onto the interconnecting shaft (Fig. 14). Fig. 12 Slide Tripod Off The Shaft 1 - TRIPOD ASSEMBLY 2 - AXLE SHAFT 3 - HALF SHAFT BOOT Fig. 14 Install CV Boot Onto Interconnecting Shaft 1 - HALF SHAFT BOOT HALF SHAFT - REAR RS 3 - 19 CV BOOT - INNER/OUTER (Continued) (4) Install the tripod assembly onto the interconnecting shaft (Fig. 15). (6) Install the new large diameter retaining clamp onto the CV joint housing. (7) 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. (8) Install the CV housing onto the interconnecting shaft and tripod assembly (Fig. 17). Fig. 15 Slide Tripod Onto The Interconnecting Shaft 1 - TRIPOD ASSEMBLY 2 - AXLE SHAFT 3 - HALF SHAFT BOOT (5) Install the snap-ring to hold the tripod assembly onto the interconnecting shaft (Fig. 16). Fig. 17 Install CV Housing 1 - HALF SHAFT JOINT HOUSING 2 - BOOT (9) Clamp the half shaft into a suitable vise with protective jaws clamped onto the interconnecting shaft. Fig. 16 Install Snap-Ring 1 2 3 4 - SNAP RING HALF SHAFT BOOT TRIPOD ASSEMBLY SNAP RING PLIERS 3 - 20 HALF SHAFT - REAR RS CV BOOT - INNER/OUTER (Continued) (10) Position the inner CV joint boot on interconnecting shaft so the raised bead on the inside of the small diameter end of the seal boot is in mating groove on interconnecting shaft (Fig. 18). Fig. 19 Crimping Tool Installed on Sealing Boot Clamp - Typical Fig. 18 Sealing Boot Installation on Interconnecting Shaft 1 2 3 4 - SEALING BOOT RAISED BEAD IN THIS AREA OF SEALING BOOT GROOVE INTERCONNECTING SHAFT 1 2 3 4 - SPECIAL TOOL C-4975-A INTERCONNECTING SHAFT CLAMP SEALING BOOT (11) Install inner CV joint seal boot to interconnecting shaft clamp evenly on sealing boot. (12) Place crimping tool C-4975-A over bridge of clamp (Fig. 19). (13) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 20). CAUTION: The boot must not be dimpled, stretched or out of shape in any way. If boot is NOT shaped correctly, equalize pressure in boot and shape it by hand. (14) Position CV boot into the CV housing retaining groove. Install the boot large diameter retaining clamp evenly onto the boot. (15) Clamp the CV joint boot to the CV joint, using required procedure for type of boot clamp application. Fig. 20 Sealing Boot Retaining Clamp Installed Typical 1 - CLAMP 2 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT RS HALF SHAFT - REAR 3 - 21 CV BOOT - INNER/OUTER (Continued) CRIMP TYPE BOOT CLAMP LATCHING TYPE BOOT CLAMP If seal boot uses crimp type boot clamp, use the following procedure to install the retaining clamp. (1) Place crimping tool C-4975-A over bridge of clamp (Fig. 21). (2) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 22). If seal boot uses low profile latching type boot clamp, use the following procedure to install the retaining clamp. (1) Place prongs of clamp locking tool in the holes of the clamp (Fig. 23). (2) Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (Fig. 24). Fig. 21 Crimping Tool Installed on Sealing Boot Clamp - Typical 1 2 3 4 - CLAMP TRIPOD JOINT HOUSING SPECIAL TOOL C-4975-A SEALING BOOT Fig. 22 Sealing Boot Retaining Clamp Installed Typical 1 - CLAMP 2 - TRIPOD HOUSING 3 - SPECIAL TOOL C-4975-A 4 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT Fig. 23 Clamping Tool Installed on Sealing Boot Clamp 1 - CLAMP 2 - TOOL YA3050, OR EQUIVALENT 3 - SEALING BOOT Fig. 24 Sealing Boot Clamp Correctly Installed 1 - INNER TRIPOD JOINT HOUSING 2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP 3 - SEALING BOOT (16) Install the half shaft into the vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) 3 - 22 PROPELLER SHAFT RS PROPELLER SHAFT TABLE OF CONTENTS page page PROPELLER SHAFT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 SPECIFICATIONS - PROPELLER SHAFT . . . . . 23 PROPELLER SHAFT DESCRIPTION WARNING: Due to propeller shaft imbalance concerns, the propeller shaft can only be serviced as an assembly. AWD models utilize a “two-piece” propeller shaft (Fig. 1) to transmit power to the rear driveline module assembly. This two-piece design consists of: • Front and rear shaft segments. • Plunging center CV joint • Center support bearing • Rubber coupler at driveline module flange The front shaft segment utilizes a CV joint at the power transfer unit connection, and a plunging CV joint at the center bearing location. The rear shaft segment utilizes a center support bearing at the forward position, and a rubber coupler at the driveline module flange. OPERATION The propeller shaft (Fig. 1) is used to transmit torque from the transaxle power transfer unit (PTU) Fig. 1 Propeller Shaft Removal/Installation 1 - PTU FLANGE 3 - REAR DRIVELINE MODULE 2 - CROSSMEMBER 4 - BOLT-PROPELLER SHAFT COUPLERT0-DRIVELINE MODULE 5 - BOLT-CENTER SUPPORT BEARING-TOCROSSMEMBER 6 - PROPELLER SHAFT ASSEMBLY PROPELLER SHAFT RS 3 - 23 PROPELLER SHAFT (Continued) to the rear driveline module of AWD equipped models. The propeller shaft front half utilizes a CV joint at the PTU flange, and a plunging CV joint at the center bearing location. These joints are flexible, allowing for torsional movement of the powertrain. The propeller shaft rear half utilizes a center support bearing, which supports this two-piece assembly. The bearing also stabilizes the rear shaft segment to minimize axle wind-up. The rubber coupler at the driveline module flange dampens out propeller shaft torsional vibrations, as the driveline module it connects to is fastened to the vehicle body. REMOVAL CAUTION: Propeller shaft removal is a two-man operation. Never allow propeller shaft to hang while connected to power transfer unit (PTU) or rear driveline module flanges. A helper is required. (1) Make sure transaxle is in neutral (N). Using chalk, mark propeller shaft flanges at PTU and rear driveline module for installation reference. (2) Remove six propeller shaft-to-power transfer unit bolts. (3) Have helper remove three propeller shaft rubber coupler-to-driveline module bolts while he/she supports rear shaft by hand. (4) Remove center bearing support-to-crossmember bolts, while supporting front shaft with two hands. (5) Lower propeller shaft assembly to ground, using care not to damage fore and aft flanges (Fig. 1). INSTALLATION CAUTION: Propeller shaft installation is a two-man operation. Never allow propeller shaft to hang while connected to power transfer unit (PTU) or rear driveline module flanges. A helper is required. (1) Make sure transaxle is in Neutral (N) position. (2) Obtain a helper and lift propeller shaft assembly into position (Fig. 1). (3) While helper supports front half of shaft level to underbody, align paint marks at driveline module flange and install three propeller shaft rubber coupler-to-rear driveline module bolts by hand. Do not torque at this time. (4) While helper supports front half of shaft level to underbody, align chalk marks at PTU flange. Install six propeller shaft-to-PTU flange bolts and torque to 30 N·m (22 ft. lbs.). Torque bolts alternately to ensure proper flange mating. (5) Place center bearing into position. Install and torque center bearing-to-crossmember bolts to 54 N·m (40 ft. lbs.). (6) Torque propeller shaft rubber coupler-to-rear driveline module assembly to 54 N·m (40 ft. lbs.). SPECIFICATIONS - PROPELLER SHAFT TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolt, Propeller Shaft Front Flange-to-PTU Flange 30 22 — Bolt, Propeller Shaft Rear Flange-to-Driveline Module Flange 54 40 — Bolt, Center Support Bearing-toBody 54 40 — 3 - 24 REAR DRIVELINE MODULE RS REAR DRIVELINE MODULE TABLE OF CONTENTS page REAR DRIVELINE MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - REAR DRIVELINE MODULE NOISE . . . . . . . . DIAGNOSIS AND TESTING - REAR DRIVELINE MODULE OPERATION . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS - REAR DRIVELINE MODULE . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS .................. BI-DIRECTIONAL OVERRUNNING CLUTCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL ASSEMBLY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . 24 . . . . . 25 . . . . . . . . . . . . . . . . . . . . . 27 . 27 . 28 . 30 . 34 . . . . . 35 . . . . . 35 . . . . . 36 . . . . . 38 page OPERATION . . . . . . . . . . . . . . . . . . . . . . . . FLUID - DIFFERENTIAL ASSEMBLY STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID DRAIN AND FILL . . . . FLUID STANDARD PROCEDURE - OVERRUNNING CLUTCH HOUSING FLUID CHANGE . . . . VISCOUS COUPLER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . TORQUE ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . INPUT FLANGE SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . OUTPUT FLANGE SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . 42 . . . 43 . . . 44 . . . 44 . . . 46 . . . 46 . . . 46 . . . 47 . . . 48 . . . 49 . . . . . 41 REAR DRIVELINE MODULE DESCRIPTION The rear driveline module assembly (Fig. 1) consists of four main components: • Bi-Directional Overrunning Clutch (BOC) • Viscous Coupling • Differential Assembly • Torque Arm The viscous coupling and bi-directional overrunning clutch are contained within an overrunning clutch housing, which fastens to the differential assembly. The overrunning clutch housing and differential assembly have unique fluid sumps, each requiring their own type and capacity of fluid. The overrunning clutch housing requires Mopart ATF+4 (Automatic Transmission Fluid—Type 9602) or equivalent. The differential assembly requires Driveline module service is limited to the following components: • Differential Assembly (serviced only as assembly) • Viscous Coupling • Bi-Directional Overrunning Clutch (BOC) • Overrunning Clutch Housing • Seals (Input Flange, Output Flange, Overrunning Clutch Housing O-rings) • • • • Input Flange/Shield Torque Arm Vents Fasteners OPERATION The primary benefits of All Wheel Drive are: • Superior straight line acceleration, and cornering on all surfaces • Better traction and handling under adverse conditions, resulting in improved hill climbing ability and safer driving. The heart of the system is an inter-axle viscous coupling. The vehicle retains predominantly frontwheel drive characteristics, but the All Wheel Drive capability takes effect when the front wheels start to slip. Under normal level road, straight line driving, 100% of the torque is allocated to the front wheels. The viscous coupling controls and distributes torque/ power to the rear wheels. The viscous coupling transmits torque to the rear wheels in proportion of the amount of the slippage at the front wheels. Thais variable torque distribution is automatic with no driver inputs required. The coupling is similar to a multi-plate clutch. It consists of a series of closely spaced discs, which are alternately connected to the front and rear drive units. The unit is totally sealed and partially filled with silicone fluid. There is no REAR DRIVELINE MODULE RS 3 - 25 REAR DRIVELINE MODULE (Continued) Fig. 1 AWD Driveline Module Assembly 1 2 3 4 5 6 7 - TORQUE ARM INPUT FLANGE FLANGE NUT WASHER SHIELD VENT O-RING 8 - WASHER 9 - BI-DIRECTIONAL OVERRUNNING CLUTCH (BOC) 10 - VISCOUS COUPLER 11 - SHIM (SELECT) 12 - O-RING 13 - DIFFERENTIAL ASSEMBLY 14 - PLUG-DIFFERENTIAL FILL adjustment, maintenance or fluid checks required during the life of the unit. The overrunning clutch allows the rear wheels to overrun the front wheels during a rapid front wheel lock braking maneuver. The overrunning action prevents any feed-back of front wheel braking torque to the rear wheels. It also allows the braking system to control the braking behavior as a two wheel drive (2WD) vehicle. The overrunning clutch housing has a separate oil sump and is filled independently from the differential. The fill plug is located on the side of the overrunning clutch case. When filling the overrunning clutch with lubricant use Mopart ATF+4 (Automatic Transmission Fluid—Type 9602) or equivalent. The differential assembly contains a conventional open differential with hypoid ring gear and pinion gear set. The hypoid gears are lubricated by SAE 80W-90 gear lubricant. 15 16 17 18 19 - PLUG-OVERRUNNING CLUTCH HOUSING DRAIN SNAP RING BEARING OVERRUNING CLUTCH HOUSING SEAL-INPUT FLANGE DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - REAR DRIVELINE MODULE NOISE Different sources can be the cause of noise that the rear driveline module assembly is suspected of making. Refer to the following causes for noise diagnosis. DRIVELINE MODULE ASSEMBLY NOISE The most important part of driveline module service is properly identifying the cause of failures and noise complaints. The cause of most driveline module failures is relatively easy to identify. The cause of driveline module noise is more difficult to identify. If vehicle noise becomes intolerable, an effort should be made to isolate the noise. Many noises that are reported as coming from the driveline module may actually originate at other sources. For example: • Tires • Road surfaces 3 - 26 REAR DRIVELINE MODULE RS REAR DRIVELINE MODULE (Continued) • Wheel bearings • Engine • Transmission • Exhaust • Propeller shaft (vibration) • Vehicle body (drumming) Driveline module noises are normally divided into two categories: gear noise or bearing noise. A thorough and careful inspection should be completed to determine the actual source of the noise before replacing the driveline module. The rubber mounting bushings help to dampen-out driveline module noise when properly installed. Inspect to confirm that no metal contact exists between the driveline module case and the body. The complete isolation of noise to one area requires expertise and experience. Identifying certain types of vehicle noise baffles even the most capable technicians. Often such practices as: • Increase tire inflation pressure to eliminate tire noise. • Listen for noise at varying speeds with different driveline load conditions • Swerving the vehicle from left to right to detect wheel bearing noise. All driveline module assemblies produce noise to a certain extent. Slight carrier noise that is noticeable only at certain speeds or isolated situations should be considered normal. Carrier noise tends to peak at a variety of vehicle speeds. Noise is NOT ALWAYS an indication of a problem within the carrier. TIRE NOISE Tire noise is often mistaken for driveline module noise. Tires that are unbalanced, worn unevenly or are worn in a saw-tooth manner are usually noisy. They often produce a noise that appears to originate in the driveline module. Tire noise changes with different road surfaces, but driveline module noise does not. Inflate all four tires with approximately 20 psi (138 kPa) more than the recommended inflation pressure (for test purposes only). This will alter noise caused by tires, but will not affect noise caused by the differential. Rear axle noise usually ceases when coasting at speeds less than 30 mph (48 km/h); however, tire noise continues, but at a lower frequency, as the speed is reduced. After test has been completed lower tire pressure back to recommended pressure. GEAR NOISE (DRIVE PINION AND RING GEAR) Abnormal gear noise is rare and is usually caused by scoring on the ring gear and drive pinion. Scoring is the result of insufficient or incorrect lubricant in the carrier housing. Abnormal gear noise can be easily recognized. It produces a cycling tone that will be very pronounced within a given speed range. The noise can occur during one or more of the following drive conditions: • Drive • Road load • Float • Coast Abnormal gear noise usually tends to peak within a narrow vehicle speed range or ranges. It is usually more pronounced between 30 to 40 mph (48 to 64 km/h) and 50 to 60 mph (80 to 96 km/h). When objectionable gear noise occurs, note the driving conditions and the speed range. BEARING NOISE (DRIVE PINION AND DIFFERENTIAL) Defective bearings produce a rough growl that is constant in pitch and varies with the speed of vehicle. Being aware of this will enable a technician to separate bearing noise from gear noise. Drive pinion bearing noise that results from defective or damaged bearings can usually be identified by its constant, rough sound. Drive pinion front bearing is usually more pronounced during a coast condition. Drive pinion rear bearing noise is more pronounced during a drive condition. The drive pinion bearings are rotating at a higher rate of speed than either the differential side bearings or the axle shaft bearing. Differential side bearing noise will usually produce a constant, rough sound. The sound is much lower in frequency than the noise caused by drive pinion bearings. Bearing noise can best be detected by road testing the vehicle on a smooth road (black top). However, it is easy to mistake tire noise for bearing noise. If a doubt exists, the tire treads should be examined for irregularities that often causes a noise that resembles bearing noise. ENGINE AND TRANSMISSION NOISE Sometimes noise that appears to be in the driveline module assembly is actually caused by the engine or the transmission. To identify the true source of the noise, note the approximate vehicle speed and/or RPM when the noise is most noticeable. Stop the vehicle next to a flat brick or cement wall (this will help reflect the sound). Place the transaxle in NEUTRAL. Accelerate the engine slowly up through the engine speed that matches the vehicle speed noted when the noise occurred. If the same noise is produced, it usually indicates that the noise is being caused by the engine or transaxle. REAR DRIVELINE MODULE RS 3 - 27 REAR DRIVELINE MODULE (Continued) DIAGNOSIS AND TESTING - REAR DRIVELINE MODULE OPERATION Driveline module operation requires relatively straight-forward diagnosis. Refer to the following chart: DRIVELINE MODULE DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Rear wheels not overrunning 1) Bi-directional overrunning clutch failure 1) Replace overrunning clutch components as required No AWD in forward or reverse directions, propeller shaft turning 1) Bi-directional overrunning clutch failure 1) Replace overrunning clutch components as required 2) Viscous coupling failure 2) Replace viscous coupling 3) Rear differential failure 3) Replace the rear differential assembly No AWD in forward or reverse directions, propeller shaft not turning 1) Power transfer unit failure. 1) Replace power transfer unit components as necessary Vibration at all speeds, continuous torque transfer 1) Mis-matched tires, worn tires on front axle. 1) Replace worn or incorrect (mis-matched) tires with same make and size REMOVAL (1) Raise vehicle on hoist. (2) Drain fluid from overrunning clutch housing and/or differential assembly if necessary. (3) Remove propeller shaft. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT REMOVAL) (4) Disconnect left and right rear halfshafts from output flanges (Fig. 2). (5) Remove (6) Position assembly and (7) Remove (Fig. 3). torque arm mount to body bolts. transmission jack to driveline module secure assembly to jack. two driveline module-to-body bolts Fig. 3 Rear Drive Line Module Assembly Mounting Bolts Fig. 2 Half Shaft Mounting Bolts 1 - SHAFT 2 - FLANGE 1 - DRIVELINE MODULE RETAINING BOLT (2) 2 - RUBBER ISOLATOR 3 - WASHER (8) Lower driveline module from vehicle and remove from jack. 3 - 28 REAR DRIVELINE MODULE RS REAR DRIVELINE MODULE (Continued) DISASSEMBLY (3) Remove input flange (Fig. 6). WARNING: Differential is only to be serviced as an assembly, and no disassembly is required. (1) Remove six torque arm-to-differential case bolts and remove torque arm assembly (Fig. 4). Fig. 6 Input Flange 1 - INPUT FLANGE/SHIELD (4) Remove input flange seal from overrunning clutch housing using suitable screwdriver (Fig. 7). Fig. 4 Torque Arm Fasteners 1 - TORQUE ARM ASSEMBLY 2 - BOLT (SIX) (2) Remove input flange nut and washer using Tool 6958 and a breaker bar (Fig. 5). Fig. 7 Input Flange Seal Removal 1 - INPUT FLANGE SEAL 2 - SCREWDRIVER Fig. 5 Input Flange Nut 1 - INPUT FLANGE 2 - TOOL 6958 REAR DRIVELINE MODULE RS 3 - 29 REAR DRIVELINE MODULE (Continued) (5) Remove four overrunning clutch housing-to-differential assembly bolts (Fig. 8) and remove housing. Fig. 8 Overrunning Clutch Housing Bolts 1 - OVERRUNNING CLUTCH HOUSING 2 - BOLT (FOUR) (6) Remove front bearing snap ring (Fig. 14). (7) Remove front bearing (Fig. 14). (8) Remove o-ring and washer from overrunning clutch assembly (Fig. 14). (9) Remove overrunning clutch assembly from viscous coupler (Fig. 9). (10) Remove viscous coupler from differential pinion shaft (Fig. 10). Fig. 10 Viscous Coupler 1 - VISCOUS COUPLER 2 - DIFFERENTIAL PINION (11) Remove shim (select) from differential pinion gear (Fig. 11). Fig. 11 Shim (Select) 1 - SHIM (SELECT) 2 - DIFFERENTIAL PINION Fig. 9 Overrunning Clutch 1 - OVERRUNNING CLUTCH 2 - VISCOUS COUPLER 3 - 30 REAR DRIVELINE MODULE RS REAR DRIVELINE MODULE (Continued) (12) Remove overrunning clutch housing large o-ring from differential assembly (Fig. 14). (13) Remove output flanges using suitable screwdrivers and wood blocks to protect casting (Fig. 12). (14) Remove output flange seals (Fig. 13). Fig. 13 Output Flange Seal Removal 1 - OUTPUT FLANGE SEAL 2 - SCREWDRIVER ASSEMBLY Fig. 12 Output Flange Removal 1 2 3 4 5 6 - WOOD BLOCK PRYBAR OUTPUT SHAFT PRYBAR WOOD BLOCK DIFFERENTIAL CASE (1) Install output flange seals using tools C4171 and 8493 (Fig. 15). (2) Install large overrunning clutch housing o-ring to differential assembly (Fig. 14). (3) Install shim to differential pinion shaft (Fig. 16). REAR DRIVELINE MODULE RS 3 - 31 REAR DRIVELINE MODULE (Continued) Fig. 14 Drive Line Module 1 - NUT, INPUT FLANGE 2 - WASHER, INPUT FLANGE NUT 6 - BEARING, FRONT 7 - SNAP RING, BEARING RETAINER 3 - INPUT FLANGE/SHIELD 4 - SEAL, INPUT FLANGE 5 - OVERRUNNING CLUTCH HOUSING BOLT 8 - O-RING 9 - WASHER 10 - BI-DIRECTIONAL OVERRUNNING CLUTCH Fig. 15 Output Flange Seal Installation 1 - DRIVER HANDLE C4171 2 - INSTALLER 8493 11 - VISCOUS COUPLER 12 - O-RING, OVERRUNNING CLUTCH HOUSING 13 - SHIM (SELECT) 14 - DIFFERENTIAL ASSEMBLY Fig. 16 Shim (Select) 1 - SHIM (SELECT) 2 - DIFFERENTIAL PINION 3 - 32 REAR DRIVELINE MODULE RS REAR DRIVELINE MODULE (Continued) (4) Install viscous coupler to differential pinion shaft (Fig. 17). (6) Install washer to overrunning clutch (Fig. 14). (7) Install o-ring to overrunning clutch (Fig. 14). (8) Align overrunning clutch ground tab to 12 o’clock position (Fig. 19). Fig. 17 Viscous Coupler 1 - VISCOUS COUPLER 2 - DIFFERENTIAL PINION (5) Install overrunning clutch assembly to viscous coupler (Fig. 18). Fig. 19 Grounding Tab at 12 O’clock 1 - OVERRUNNING CLUTCH 2 - GROUND TAB (9) Install overrunning clutch housing into position, making sure ground tab engages with notch in housing (Fig. 20). Fig. 18 Overrunning Clutch 1 - OVERRUNNING CLUTCH 2 - VISCOUS COUPLER Fig. 20 Overrunning Clutch Housing 1 - OVERRUNNING CLUTCH HOUSING 2 - NOTCH REAR DRIVELINE MODULE RS 3 - 33 REAR DRIVELINE MODULE (Continued) (10) Install and torque overrunning clutch housing-to-differential assembly bolts (Fig. 21) to 60 N·m (44 ft. lbs.). (12) Install flange/shield assembly (Fig. 23). Fig. 23 Input Flange/Shield 1 - INPUT FLANGE/SHIELD Fig. 21 Overrunning Clutch Housing Bolts 1 - OVERRUNNING CLUTCH HOUSING 2 - BOLT (FOUR) (13) Install input flange washer and nut. Using tool 6958 (Fig. 24), torque nut to 135 N·m (100 ft. lbs.). (11) Install input flange seal using tool 8802 (Fig. 22). Fig. 24 Input Flange Nut Fig. 22 Input Flange Seal Installation 1 - TOOL 8802 2 - HAMMER 1 - INPUT FLANGE 2 - TOOL 6958 3 - 34 REAR DRIVELINE MODULE RS REAR DRIVELINE MODULE (Continued) (14) Install torque arm assembly into position. Install and torque torque arm-to-differential assembly bolts (Fig. 25) to 60 N·m (44 ft. lbs.). (3) Remove transmission jack. (4) Install and torque torque arm mount-to-body bolts to 54 N·m (40 ft. lbs.). (5) Install halfshafts to differential output flanges and torque bolts (Fig. 27) to 61 N·m (45 ft. lbs.). Fig. 27 Half Shaft Mounting Bolts Fig. 25 Torque Arm Fasteners 1 - TORQUE ARM ASSEMBLY 2 - BOLT (SIX) INSTALLATION (1) Install rear driveline module assembly to transmission jack and secure. (2) Raise rear driveline module into position and install and torque mounting bolts (Fig. 26) to 54 N·m (40 ft. lbs.). Fig. 26 Rear Drive Line Module Assembly Rear Mounting Bolts 1 - DRIVELINE MODULE RETAINING BOLT (2) 2 - RUBBER ISOLATOR 3 - WASHER 1 - SHAFT 2 - FLANGE (6) Install propeller shaft. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT INSTALLATION) (7) Lower vehicle. REAR DRIVELINE MODULE RS 3 - 35 REAR DRIVELINE MODULE (Continued) SPECIFICATIONS - REAR DRIVELINE MODULE TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolt, Driveline Module-to-Body 54 40 — Bolt, Halfshaft-to-Ouput Flange 61 45 — Bolt, Overrunning Clutch Housing-to-Differential 60 44 — Bolt, Torque Arm-to-Differential Assembly 60 44 — Bolt, Torque Arm Mount-to-Body 54 40 — Nut, Input Flange 135 100 — Plug, Differential Drain/Fill 35 26 — Plug, Overrunning Clutch Housing Drain/Fill 30 22 — Vent, Differential/Overrunning Clutch Housing 12 — 110 SPECIAL TOOLS Tool 6958 Tool 8493 Tool 8802 3 - 36 REAR DRIVELINE MODULE BI-DIRECTIONAL OVERRUNNING CLUTCH DESCRIPTION The bi-directional overrunning clutch (BOC) (Fig. 28) works as a mechanical disconnect between the front and rear axles, preventing torque from being transferred from the rear axle to the front. The BOC is a simply an overrunning clutch which works in both clockwise and counter-clockwise rotations. This means that when the output (the rear axle) is rotating faster in one direction than the input (front axle), there is no torque transmission. But when the input speed is equal to the output speed, the unit becomes locked. The BOC provides significant benefits regarding braking stability, handling, and driveline durability. Disconnecting the front and the rear driveline during braking helps to maintain the braking stability of an AWD vehicle. In an ABS/braking event, the locking of the rear wheels must be avoided for stability reasons. Therefore brake systems are designed to lock the front wheels first. Any torque transfer from the rear axle to the front axle disturbs the ABS/braking system and causes potential instabilities on a RS slippery surface. The BOC de-couples the rear driveline as soon the rear wheels begin to spin faster than the front wheels (front wheels locked) in order to provide increased braking stability. Furthermore the BOC also reduces the likelihood of throttle off over-steer during cornering. In a throttle off maneuver, the BOC once again de-couples the rear driveline forcing all the engine brake torque to the front wheels. This eliminates the chance of lateral slip on the rear axle and increases it on the front. The vehicle will therefore tend to understeer, a situation which is considered easier to manage in most circumstances. During this maneuver, and during the ABS braking event, the BOC does not transmit torque through to the rear wheels. The rear driveline module, with the BOC, will perform the same as a front wheel drive vehicle during these events. The gear ratio offset between the front and rear differentials force the BOC into the overrunning mode most of the time. This allows BOC to significantly reduce the rolling resistance of the vehicle, which improves fuel consumption, allows the downsizing of the driveline components, and prevents the PTU and propshaft joints from overheating. REAR DRIVELINE MODULE RS BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) Fig. 28 Bi-directional Overrunning Clutch and Viscous Coupler 1 2 3 4 5 - POWERFLOW - BOC OVERUNNING POWERFLOW - BOC LOCKED BOC GROUND TAB FRICTION BRAKE SHOES BOC ROLLERS 6 7 8 9 - VISCOUS COUPLER BOC ROLLER CAGE BOC INPUT SHAFT INPUT FLANGE 3 - 37 3 - 38 REAR DRIVELINE MODULE RS BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) OPERATION In order to achieve all-wheel drive operation in reverse, the overrunning clutch locking functional direction must be reversible. The bi-directional overrunning clutch (BOC) changes the operational mode direction depending on the propeller shaft direction. The propeller shaft rotates in the clockwise (when viewed from the front) direction when the vehicle is moving forward, which indexes the BOC to the forward overrunning position. When the vehicle is in reverse, the propeller shaft will rotate counter-clockwise and index the BOC to the reverse overrunning position. The BOC acts as a mechanical stator. It is active (transmitting torque), or it is not active and in overrunning mode (not transmitting torque). This “all or nothing” approach to torque transfer would cause a sudden application of all available power to the rear wheels, which is not desirable. Therefore it is run in series with a viscous coupler to smooth, dampen, and limit the transmission of torque to the rear axle and to prevent a step style torque input to the rear axle. STEADY STATE, LOW TO MODERATE SPEED, NO FRONT WHEEL SLIP, FORWARD DIRECTION During normal driving conditions, (no wheel slip), the inner shaft (front axle) and outer race (viscous coupler) are running at different speeds due to the different gear ratios between the front and rear differentials. In this condition, the outer race is always spinning faster (overdriving between 5-32 rpm) than the inner shaft. When the BOC (Fig. 29) is running under these conditions, at low vehicle speeds the drag shoes and the cage keep the rollers up on the left side (forward side) of the inner shaft flats. This is what is known as “overrunning mode.” Notice that when the clutch is in overrunning mode, the rollers are spinning clockwise and with the outer race, thus no torque is being transferred. Fig. 29 BOC Operation at Low Speeds With No Front Wheel Slip 1 - CAGE 2 - ROLLER 3 - INPUT SHAFT are rotating at the same speed. The rollers are pinched at this point and will stay locked until a torque reversal (no front wheel slip) occurs. When locked, the viscous coupler slips during the torque transfer and the amount of torque transferred is dependent on the coupling characteristic and the amount of front wheel slip. NOTE: Low speed, forward and reverse operation is identical, just in opposite directions. (Fig. 29) shows forward direction in reverse the rollers are on the other side of the flats due to a reversal of the cage force. TRANSIENT CONDITION (BOC LOCKED), FRONT WHEEL SLIP, FORWARD DIRECTION When the front wheels lose traction and begin to slip, the propeller shaft and rear axle pinion speed difference decreases to zero. At this point the input shaft (cam) becomes the driving member of the BOC (Fig. 30), compressing the rollers against the outer race. This locks the input shaft with the outer race and transmits torque to the housing of the viscous coupler, that in turn transmits torque to the rear axle pinion. It should also be noted that when the device is locked, the inner shaft and the outer race Fig. 30 BOC Operation with Front Wheel Slip REAR DRIVELINE MODULE RS 3 - 39 BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) STEADY STATE, HIGH SPEED, NO WHEEL SLIP The roller cage positions the rollers on the input shaft flats during low and high speed overrunning and during initial BOC lockup. The roller cage is rotating at input shaft (propeller shaft) speed at all times. At low speeds, the friction shoes (Fig. 31) are pressed against the friction ground via the garter spring (Fig. 32), creating a drag force on the roller cage. The drag force positions the cage, which in turn positions the rollers to one side of the flat. The direction of this drag force (position of the roller) is dependent on the input (propeller shaft) rotational direction. Since the rollers are always in contact with the outer race, due to centrifugal forces, the rollers want to follow the outer race due to drag. During overrunning operation, the outer race is rotating faster than the input; causing the rollers to want to traverse the flat from one side to the other. During low speeds, the brake shoes counteract this effect. To avoid excessive wear, the ground shoes are designed to lift off from the friction ground due to centrifugal forces at higher rotational speeds. Fig. 32 Location of the Grounding Element 1 - DIFFERENTIAL HOUSING 2 - GROUND TAB 3 - GARTER SPRING migrate to the opposite side of the flat due to the drag force of the outer race. This would result in system lock-up. (Fig. 34) shows the BOC as it crosses the speed where the brake shoe force is overcome by the roller drag on the outer race. Notice that the roller is locking up on the opposite side of the flat and the cage supplies no force on the rollers. Fig. 31 Front View of BOC 1 2 3 4 - GARTER SPRING FRICTION BRAKE SHOES FRICTION GROUND CONNECTED TO GROUND TAB INPUT SHAFT To keep the rollers in the overrunning position and avoid undesired 9high speed lockup9, a high speed latch (Fig. 33) positions the cage before the ground shoes lift off. A further explanation of the high speed effects follows as well. Utilizing only the friction shoes approach means that at high speed the required ground shoe drag torque would cause excessive brake shoe wear or the roller will begin to Fig. 33 BOC High Speed Latch (Not Engaged) 1 2 3 4 - TOOTH (TWO PLACES) GARTER SPRING TABS AT BOTH ENDS FIT INTO SLOTS IN CAGE TWO PART DESIGN 3 - 40 REAR DRIVELINE MODULE RS BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) Fig. 34 BOC Operation During High Speed Lock-up Without High Speed Latch This lock-up is not desired, and requires the use of another mechanism to prevent the lock-up. The device that prevents undesired high-speed lock-up is called a 9high speed latch9. Similar to the friction shoes, the two-piece highspeed latch will separate from each other at high rotational speeds due to centrifugal effects. (Fig. 35) shows the high speed latch engaged. The gap 9x9 increases with speed, eventually locking into one of the slots in the BOC shaft. When the high-speed latch is activated (propeller shaft speed reaches X amount), the cage is partially fixed, and cannot lock on the wrong side of the flat as shown (Fig. 34). The high speed latch is a one way device and does not prevent high-speed lockup in the reverse direction. At high speeds, the BOC provides the same function as low speeds, transferring torque to the viscous coupler only when front wheel slip overcomes the axle ratio offset. Fig. 35 High Speed Latch Engaged 1 - CAGE FORCE EXERTED BY ROLLERS AT HIGH SPEED REAR DRIVELINE MODULE RS 3 - 41 BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) At high speed, the rollers are forced outward to the outer race because of centrifugal force. At high speeds, the friction shoes can no longer prevent lockup. When the teeth on the high-speed latch engage into the input shaft, it keeps the rollers centered above the flats because the tabs on the latch are locked into the cage. (Fig. 36) shows the roller configuration with the High-Speed Latch engaged. Fig. 37 BOC Input Shaft 1 - GROOVED AREA (2 LOCATIONS) 2 - ROLLER MATING SURFACE Fig. 36 BOC Operation at High Speed with High Speed Latch On the BOC shaft, the high speed latch teeth lock up in the grooved areas, shown in (Fig. 37), when the turning speed reaches the critical value. (Fig. 37) also shows the outer race/viscous coupler. Notice the surface (outer race) the rollers mate against when transferring torque. • The ring gear (bolted to the differential case) rotates the case • The differential pinion gears (mounted on the pinion mate shaft in the case) rotate the side gears • The side gears (splined to the axle shafts) rotate the shafts During straight-ahead driving, the differential pinion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears. As a result, the pinion gears revolve with the pinion mate shaft but do not rotate around it (Fig. 38). DIFFERENTIAL ASSEMBLY DESCRIPTION The differential gear system divides the torque between the axle shafts. It allows the axle shafts to rotate at different speeds when turning corners. Each differential side gear is splined to an axle shaft. The pinion gears are mounted on a pinion mate shaft and are free to rotate on the shaft. The pinion gear is fitted in a bore in the differential case and is positioned at a right angle to the axle shafts. OPERATION In operation, power flow occurs as follows: • The pinion gear rotates the ring gear Fig. 38 Differential Operation—Straight Ahead Driving 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED 2 - PINION GEAR 3 - SIDE GEAR 4 - PINION GEARS ROTATE WITH CASE 3 - 42 REAR DRIVELINE MODULE RS DIFFERENTIAL ASSEMBLY (Continued) When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns. To accomplish this, the differential allows the axle shafts to turn at unequal speeds (Fig. 39). In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed. Fig. 40 Differential Drain Plug 1 - DIFFERENTIAL DRAIN PLUG Fig. 39 Differential Operation—On Turns 1 - PINION GEARS ROTATE ON PINION SHAFT FLUID - DIFFERENTIAL ASSEMBLY STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID DRAIN AND FILL The drain plug (Fig. 40) for the differential assembly is located in the bottom of the differential assembly case, toward the rear of the unit. The fill plug (Fig. 41) for the differential assembly is located on the rear of the assembly case. The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. (1) Raise the vehicle on a hoist. (2) Position a drain pan under the differential drain plug (Fig. 40). (3) Remove the drain plug and allow the fluid to drain into the pan. (4) Install the drain plug and torque to 35 N·m (26 ft. lbs.). (5) Re-position the drain pan under the differential fill plug. (6) Remove the differential fill plug (Fig. 41). Fig. 41 Differential Fill Plug 1 - DIFFERENTIAL FILL PLUG REAR DRIVELINE MODULE RS 3 - 43 FLUID - DIFFERENTIAL ASSEMBLY (Continued) (7) Using a suction gun (Fig. 42) or equivalent, fill the differential assembly with 0.7 L (1.48 pts.) of Mopart Gear and Axle Lubricant (80W-90). (8) Install the fill plug and torque to 35 N·m (26 ft. lbs.). (3) Remove overrunning clutch housing drain plug and drain fluid (Fig. 43). (4) Install the drain plug and torque to 30 N·m (22 ft. lbs.). (5) Re-position the drain pan under the overrunning clutch housing fill plug. (6) Remove fill plug (Fig. 44). Fig. 42 Filling Differential 1 - DIFFERENTIAL ASSEMBLY 2 - SUCTION GUN FLUID STANDARD PROCEDURE - OVERRUNNING CLUTCH HOUSING FLUID CHANGE (1) Raise vehicle on hoist. (2) Position a drain pan under overrunning clutch housing drain plug. Fig. 44 Overrunning Clutch Housing Fill Plug 1 - OVERRUNNING CLUTCH HOUSING FILL PLUG 2 - FUEL TANK (7) Using a suction gun (Fig. 45), add 0.58 L (1.22 pts.) of Mopart ATF+4 (Automatic Transmission Fluid—Type 9602). Fig. 45 Filling Overrunning Clutch Case 1 - OVERRUNNING CLUTCH HOUSING FILL HOLE 2 - SUCTION GUN Fig. 43 Overrunning Clutch Case Drain Plug 1 - OVERRUNNING CLUTCH HOUSING DRAIN PLUG (8) Install fill plug and torque to 30 N·m (22 ft. lbs.). 3 - 44 REAR DRIVELINE MODULE VISCOUS COUPLER DESCRIPTION The heart of the all-wheel drive system is the inter-axle viscous coupling and bi-directional overrunning clutch. Under normal driving the vehicle retains predominantly front wheel drive characteristics. The all-wheel drive takes effect when the front wheels start to slip. Under normal level road, straight line driving, 100% of the torque is allocated to the front wheels. The viscous coupler allows more torque to the rear wheels in accordance with the amount of slippage at the front wheels. The variable torque distribution is automatic with no driver inputs required. OPERATION The viscous coupler (Fig. 46) is a housing nearly filled with a high viscosity silicone liquid and thin metal plates alternately splined to an inner and outer drum. The viscous coupler provides torque in the following modes: • Shear mode (normal operation) • Hump mode (locked mode) RS The inner plates are slotted around the radius and the outer plates have holes in them. In the shear mode (normal operation), the plates are evenly spaced and the torque is created by the shearing of the plates through the fluid and 90-100% of the torque is applied to the rear axle. During the shear mode, a fluid flow pattern is created from this design (holes and slots). This fluid flow causes high pressure on each side of each pair of plates and low pressure between each pair of plates. When a high speed difference (shear) occurs because of loss of traction (one axle spinning faster than the other), the silicone fluid expands as it heats from this shearing. When the silicone expands to fill the viscous coupler completely, this pressure difference is high enough to squeeze each pair of plates together. The resulting hump torque is up to 8 times higher than the shear torque. When the viscous coupler is in the hump mode, it does not lock the axles (undifferentiated 4-Wheel Drive). It controls the amount of slippage while delivering maximum power to the axle having greatest traction. Once the speed difference equalizes the fluid and plates cool down and the viscous coupler goes back to the shear mode. REAR DRIVELINE MODULE RS VISCOUS COUPLER (Continued) Fig. 46 Bi-directional Overrunning Clutch (BOC) and Viscous Coupler Powerflow 1 2 3 4 5 - POWERFLOW - BOC OVERUNNING POWERFLOW - BOC LOCKED BOC GROUND TAB FRICTION BRAKE SHOES BOC ROLLERS 6 7 8 9 - VISCOUS COUPLER BOC ROLLER CAGE BOC INPUT SHAFT INPUT FLANGE 3 - 45 3 - 46 REAR DRIVELINE MODULE RS TORQUE ARM REMOVAL (1) Raise vehicle on hoist. (2) Remove rear driveline module assembly. (Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR DRIVELINE MODULE - REMOVAL) (3) Remove six torque arm-to-differential assembly bolts (Fig. 47). Remove torque arm. Fig. 48 Input Flange Nut 1 - INPUT FLANGE 2 - TOOL 6958 Fig. 47 Torque Arm Fasteners 1 - TORQUE ARM ASSEMBLY 2 - BOLT (SIX) INSTALLATION (1) Install six torque arm-to-differential assembly bolts (Fig. 47) and torque to 60 N·m (44 ft. lbs.). (2) Install rear driveline module assembly. (Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR DRIVELINE MODULE - INSTALLATION) (3) Lower vehicle. INPUT FLANGE SEAL REMOVAL (1) Raise vehicle on hoist. (2) Remove propeller shaft. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT REMOVAL) (3) Using tool 6958, remove input flange nut and washer (Fig. 48). (4) Remove input flange (Fig. 49). Fig. 49 Input Flange 1 - INPUT FLANGE/SHIELD REAR DRIVELINE MODULE RS 3 - 47 INPUT FLANGE SEAL (Continued) (5) Using suitable screwdriver, remove input flange seal from overrunning clutch housing (Fig. 50). (2) Install input flange (Fig. 52). Fig. 52 Input Flange 1 - INPUT FLANGE/SHIELD Fig. 50 Input Flange Seal Removal 1 - INPUT FLANGE SEAL 2 - SCREWDRIVER (3) Install flange nut and washer. Using tool 6958, torque flange nut to 135 N·m (100 ft. lbs.) (Fig. 53). INSTALLATION (1) Using tool 8802, install input flange seal to overrunning clutch case (Fig. 51). Fig. 53 Input Flange Nut 1 - INPUT FLANGE 2 - TOOL 6958 Fig. 51 Input Flange Seal Installation 1 - TOOL 8802 2 - HAMMER (4) Install propeller shaft. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT INSTALLATION) (5) Lower vehicle. 3 - 48 REAR DRIVELINE MODULE RS OUTPUT FLANGE SEAL REMOVAL (1) Raise vehicle on hoist. (2) Remove rear halfshaft inner joint at differential output flange (Fig. 54). Fig. 55 Output Flange Removal Fig. 54 Inner Half Shaft Bolts 1 - SHAFT 2 - FLANGE (3) Using two screwdrivers and wood blocks to protect differential housing casting, pry output flange out of differential (Fig. 55). (4) Use suitable screwdriver to remove output flange seal (Fig. 56). 1 2 3 4 5 6 - WOOD BLOCK PRYBAR OUTPUT SHAFT PRYBAR WOOD BLOCK DIFFERENTIAL CASE Fig. 56 Output Flange Seal Removal 1 - OUTPUT FLANGE SEAL 2 - SCREWDRIVER REAR DRIVELINE MODULE RS 3 - 49 OUTPUT FLANGE SEAL (Continued) INSTALLATION (1) Install output flange seal to differential housing using tool C4171A and 8493 (Fig. 57). (4) Install and torque bolts to 61 N·m (45 ft. lbs.) (Fig. 58). Fig. 58 Inner Half Shaft Bolts 1 - SHAFT 2 - FLANGE Fig. 57 Output Flange Seal Installation 1 - DRIVER HANDLE C4171 2 - INSTALLER 8493 (2) Install ouput flange to differential assembly. Verify that it is seated all the way into position by attempting to pull out by hand. (3) Install rear halfshaft inner joint to output flange. (5) Check differential assembly fluid level and adjust as required. (Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR DRIVELINE MODULE/FLUID STANDARD PROCEDURE) HORN RS 8H - 1 HORN TABLE OF CONTENTS page HORN SYSTEM DESCRIPTION . . . . . . . . . OPERATION . . . . . . . . . . . DIAGNOSIS AND TESTING HORN DIAGNOSIS AND TESTING REMOVAL ............ .................1 .................1 HORN SYSTEM . . . 1 HORN . . . . . . . . . . 3 .................4 page INSTALLATION . . . . . . . . . HORN RELAY DIAGNOSIS AND TESTING REMOVAL ............ INSTALLATION . . . . . . . . . HORN SWITCH DESCRIPTION . . . . . . . . . .................4 HORN RELAY . . . . 5 .................5 .................5 .................5 HORN SYSTEM DIAGNOSIS AND TESTING - HORN SYSTEM DESCRIPTION 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. WARNING: ON VEHICLES EQUIPPED WITH AIRBAG, REFER TO ELECTRICAL, RESTRAINTS FOR SAFETY PRECAUTIONS. DISCONNECT THE NEGATIVE CABLE FROM THE BATTERY BEFORE SERVICING COMPONENTS INVOLVING THE AIRBAG SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG AND PERSONAL INJURY CAN RESULT. The horn circuit consists of a horn switch, clockspring, horn relay, horns and Integrated Power Module (IPM). The horn switch is a membrane switch located in the airbag trim cover. The horns are located forward of the left front wheel behind the bumper fascia. OPERATION The horn relay plugs into the Integrated Power Module (IPM) which is located in the engine compartment. For circuit information and component locations, 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 pinout information and location views for the various wire harness connectors, splices and grounds. The horns will not function if the switch is “CLOSED” for more than 30 seconds. Once the switch is “OPEN”, a 20–30 second delay will occur before the horns are functional again. Refer to Horn System Test below. If the horn does not sound, check horn fuse located in the Integrated Power Module (IPM). If the fuse is blown, replace with the correct fuse. If the horns fail to sound and the new fuse blows when depressing the horn switch, a short circuit in the horn or the horn wiring between the fuse terminal and the horn is responsible, or a defective horn switch allowed the horn to burn out is responsible. If the fuse is OK, test horn relay (Refer to 8 ELECTRICAL/HORN/HORN RELAY - DIAGNOSIS AND TESTING). If the relay is OK, test horn. Refer to Horn System Test. CAUTION: Continuous sounding of horn may cause horn failure. Should the horn sound continuously: • Unplug the horn relay from IPM. • Refer to (Refer to 8 - ELECTRICAL/HORN/ HORN RELAY - DIAGNOSIS AND TESTING). 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. 8H - 2 HORN RS HORN SYSTEM (Continued) HORN SYSTEM TEST CONDITION HORN SOUNDS CONTINUOUSLY. NOTE: IMMEDIATELY UNPLUG HORN RELAY IN THE IPM. HORN SOUND INTERMITTENTLY AS THE STEERING WHEEL IS TURNED. HORN DOES NOT SOUND POSSIBLE CAUSE CORRECTION (1) FAULTY HORN RELAY. (1) REFER TO HORN RELAY TEST. (2) HORN CONTROL CIRCUIT TO RELAY SHORTED TO GROUND. (2) CHECK TERMINAL 85 IN IPM FOR CONTINUITY TO GROUND. IF CONTINUITY TO GROUND INDICATES: (A) STEERING WHEEL HORN SWITCH/LEAD SHORTED TO GROUND. (B) WIRING HARNESS SHORTED TO GROUND. FIND THE SHORT AND REPAIR AS NECESSARY. (3) PINCHED HORN SWITCH WIRE UNDER DRIVER AIRBAG MODULE. (3) REPLACE DRIVER AIRBAG MODULE TRIM COVER. (4) FAULTY HORN SWITCH. (4) REPLACE DRIVER AIRBAG MODULE TRIM COVER. (5) FAULTY CLOCKSPRING. (5) REPLACE CLOCKSPRING. (6) FAULTY FRONT CONTROL MODULE. (6) REFER TO ELECTRONIC CONTROL MODULES/FRONT CONTROL MODULE. (1) HORN RELAY CONTROL CIRCUIT X3 IS SHORTED TO GROUND INSIDE STEERING COLUMN OR WHEEL. (1) REMOVE DRIVER AIRBAG MODULE AND/OR WHEEL. CHECK FOR RUBBING OR LOOSE WIRE/CONNECTOR, REPAIR AS NECESSARY. (2) PINCHED HORN SWITCH WIRE UNDER DRIVER AIRBAG MODULE. (2) REPLACE DRIVER AIRBAG MODULE TRIM COVER. (3) FAULTY HORN SWITCH. (3) REPLACE DRIVER AIRBAG MODULE TRIM COVER. (4) FAULTY CLOCKSPRING. (4) REPLACE CLOCKSPRING. (1) CHECK FUSE 8 IN INTELLIGENT POWER MODULE. (1) REPLACE FUSE IF BLOWN REPAIR AS NECESSARY. (2) NO VOLTAGE AT HORN RELAY TERMINALS 30 & 86, AND FUSE IS OK. (2) NO VOLTAGE, REPAIR THE CIRCUIT AS NECESSARY. (3) OPEN CIRCUIT FROM TERMINAL 85 OF THE HORN RELAY TO HORN SWITCH, X3 CIRCUIT. (3) REPAIR CIRCUIT AS NECESSARY. (4) FAULTY OR DAMAGED HORN. (4) VOLTAGE AT HORN WHEN HORN SWITCH IS PRESSED, REPLACE HORN. HORN RS 8H - 3 HORN SYSTEM (Continued) CONDITION FUSE BLOWS WHEN HORN SOUNDS FUSE BLOWS WITHOUT BLOWING HORN POSSIBLE CAUSE CORRECTION (5) FAULTY HORN SWITCH. (5) REPLACE DRIVER AIRBAG MODULE TRIM COVER. (6) FAULTY CLOCKSPRING. (6) REPLACE CLOCKSPRING. (7) FAULTY FRONT CONTROL MODULE. (7) REFER TO ELECTRONIC CONTROL MODULES/FRONT CONTROL MODULE. (1) SHORT CIRCUIT IN HORN OR HORN WIRING. (1) REMOVE HORN RELAY, CHECK FOR SHORTED HORN OR HORN WIRING. DISCONNECT HORN WIRE HARNESS TO ISOLATE SHORT AND REPAIR AS NECESSARY. (2) FAULTY CLOCKSPRING. (2) REPLACE CLOCKSPRING. (1) SHORT CIRCUIT. (1) REMOVE RELAY, INSTALL NEW FUSE, IF FUSE DOES NOT BLOW REPLACE HORN RELAY. IF FUSE BLOWS WITH RELAY REMOVED, CHECK FOR SHORT TO GROUND WITH OHMMETER ON CIRCUIT BETWEEN TERMINALS 30 & 86 AND THE FUSE TERMINAL. REPAIR AS NECESSARY. (2) FAULTY CLOCKSPRING. (2) REPLACE CLOCKSPRING. HORN DIAGNOSIS AND TESTING - HORN HORN (1) Disconnect wire connector at horn. (2) Using a voltmeter, connect one lead to ground terminal and the other lead to the positive wire terminal (Fig. 1). (3) Depress the horn switch, battery voltage should be present. (4) If no voltage, refer to HORNS WILL NOT SOUND. If voltage is OK, go to step Step 5. (5) Using ohmmeter, test ground wire for continuity to ground. (6) If no ground repair as necessary. (7) If wires test OK and horn does not sound, replace horn. HORNS SOUND CONTINUOUSLY CAUTION: Continuous sounding of horns may cause relay to fail. The horn switch (membrane) sometimes can be the cause without the switch being depressed. (1) Remove the horn relay from the intelligent power module. (2) Using a continuity tester, test continuity from the X3 cavity of the horn relay to ground. 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. (a) If continuity is detected, proceed to step Step 3. (b) If NO continuity, replace the horn relay. (3) Remove the airbag trim cover from the steering wheel and disengage horn connector. (4) Install horn relay into Integrated Power Module (IPM). (a) If horn does not sound, replace airbag trim cover. (b) If horn sounds, repair grounded X3 circuit from IPM to clockspring in the steering column. HORNS WILL NOT SOUND Check horn fuse # 8 in the IPM. If fuse is blown, check for a shorted switch in the airbag module. and refer to FUSE BLOWN section. If fuse is OK, refer to FUSE OK section. 8H - 4 HORN RS HORN (Continued) FUSE BLOWN (1) Verify condition of battery terminals and voltage, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING). If battery connections and battery charge is OK proceed to Step 2. (2) Using a voltmeter, test for battery voltage at both sides of horn fuse 7. If voltage is OK, on both sides of fuse, proceed to Fuse OK. If voltage is OK, on one side of fuse, the fuse is blown, proceed to Step 3. (3) Using a suitable ammeter in place of the fuse, test amperage draw of the horn circuit. If amperage draw is greater than 20 amps without the horn switch depressed, a grounded circuit exists between the fuse and the horn relay. Proceed to Step 4. If amperage draw is greater than 20 amps with the horn switch depressed, a grounded circuit exists between the horn relay and the horn. Proceed to step Step 5. (4) Remove the horn relay from the IPM. If the amperage draw drops to 0 amps, the horn switch or circuit is shorted. If the amperage draw does not drop to 0 amps, repair short at the IPM. (5) Disengage a wire connector from one of the horns. If amperage drops and the connected horn sounds, replace the faulty horn. If amperage does not drop with both horns disconnected and the horn switch depressed, proceed to Step 6. (6) Using a continuity tester, with the horns disconnected test continuity of the X2 cavity of the horn relay to ground. If continuity is detected, the circuit is grounded between the Junction Block and the horns. Locate and repair pinched harness. FUSE OK (1) Remove the horn relay from the intelligent power module. (2) Using a continuity tester, Depress horn switch and test continuity from the X3 cavity of the horn relay to ground. (a) If continuity is detected, proceed to Step 3. (b) If NO continuity, proceed to Step 4. (3) Using a suitable jumper wire, jump across the fuse F62 cavity and the X2 cavity of the horn relay in the Junction Block. (a) If the horn sounds, replace the horn relay. (b) If the horn does not sound, proceed to Step 4. (4) Remove airbag trim cover from steering wheel. Refer to ELECTRICAL, RESTRAINTS. (5) Test continuity across horn switch connectors with horn switch depressed. (a) If continuity is detected, repair open circuit between the relay and the horn switch. (b) If NO continuity, replace airbag trim cover. (6) Install horn relay into intelligent power module. (7) Disengage wire connectors from horns. (8) Using a voltmeter, with the horn switch depressed test voltage across horn connector terminals of the wire harness (Fig. 1). (a) If voltage is detected, replace horns. (b) If NO voltage, proceed to step Step 9. Fig. 1 Horn Connector (9) With the horn switch depressed, test for voltage between the X2 circuit and ground. (a) If voltage OK, repair system ground at right cowl area. (b) If NO voltage, repair open X2 circuit between the relay and the horns. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Hoist and support the front of the vehicle on safety stands. (3) From behind the front fascia and forward of the left front wheel, disconnect the wire connectors from horn. (4) Remove the mounting bracket attaching nut from the bottom of radiator closure panel. Do not remove the horn from mounting bracket. (5) Separate the horn(s) from vehicle. INSTALLATION (1) (2) (3) (4) (5) Install the horns to the vehicle. Install the mounting bracket fastener. Reconnect the wire connectors to the horns. Lower the vehicle. Reconnect the battery negative cable. HORN RS HORN RELAY DIAGNOSIS AND TESTING - HORN RELAY (1) Remove horn relay. (2) Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance. If resistance not OK, replace relay. (3) Test for continuity between ground and terminal 85 of horn relay. (a) When the horn switch is not depressed, no continuity should be present. (b) Continuity to ground when horn switch is depressed. (c) If continuity is not correct repair horn switch or wiring as necessary. (4) Using voltmeter, test voltage at: (a) Terminals 30 and 86 of the horn relay to body ground. (b) If NO voltage check fuse 8 of the intelligent power module. (c) If incorrect voltage, repair as necessary. (5) Insert a jumper wire between terminal 30 and 87 of the intelligent power module. (a) If horn sounds replace relay. 8H - 5 (b) If the horn does not sound, install horn relay and refer to Horn Test. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove cover from the intelligent power module. (3) Remove relay from intelligent power module. INSTALLATION (1) Push relay into intelligent power module. (2) Install cover. (3) Reconnect battery negative cable. HORN SWITCH DESCRIPTION The horn switch is molded into the airbag trim cover. The horn switch can not be serviced separately. For service procedures, refer to ELECTRICAL / RESTRAINTS. ENGINE RS 9-1 ENGINE TABLE OF CONTENTS page page ENGINE 2.4L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE 3.3/3.8L . . . . . . . . . . . . . . . . . . . . . . . . . 74 ENGINE 2.4L TABLE OF CONTENTS page ENGINE 2.4L DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 3 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 4 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6 DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . . . . . . . . . 8 DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . . 9 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STANDARD PROCEDURE STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 10 STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS . . . . . . . . . 10 STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE . . . . . . . . . . . . . . . . . . . . . 10 STANDARD PROCEDURE - FORM-INPLACE GASKETS AND SEALERS . . . . . . . . . 11 STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION . . . . . . . . 11 STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL - ENGINE ASSEMBLY . . . . . . . . . . . 12 INSTALLATION - ENGINE ASSEMBLY . . . . . . . . 16 SPECIFICATIONS SPECIFICATIONS - 2.4L ENGINE . . . . . . . . . 17 SPECIFICATIONS - TORQUE . . . . . . . . . . . . 20 SPECIAL TOOLS 2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 21 page AIR CLEANER ELEMENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . AIR CLEANER HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL - CYLINDER HEAD . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ......................... INSTALLATION - CYLINDER HEAD . . . . . . . . . CAMSHAFT OIL SEAL(S) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT(S) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ......................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . INTAKE/EXHAUST VALVES & SEATS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . 24 . 24 . 24 . 24 . 24 . 24 . 25 . 26 . 26 . 26 . 28 . 28 . 29 . 29 . 29 . 29 . 29 . 30 . 30 . 31 . 31 . 31 . 31 . 32 . 32 9-2 ENGINE 2.4L VALVE SPRINGS & SEALS REMOVAL REMOVAL - CYLINDER HEAD ON . . . . . REMOVAL - CYLINDER HEAD OFF . . . . INSPECTION ...................... INSTALLATION INSTALLATION - CYLINDER HEAD ON . INSTALLATION - CYLINDER HEAD OFF HYDRAULIC LASH ADJUSTERS DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . ROCKER ARMS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ...................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . ENGINE BLOCK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING . . . . . . . . . . STANDARD PROCEDURE - CYLINDER BORE HONING . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ...................... CONNECTING ROD BEARINGS STANDARD PROCEDURE CONNECTING ROD - FITTING . . . . . . . CRANKSHAFT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ...................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE - MAIN BEARING FITTING . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT OIL SEAL - FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT OIL SEAL - REAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . PISTON & CONNECTING ROD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . PISTON RINGS STANDARD PROCEDURE PISTON RING - FITTING . . . . . . . . . . . . VIBRATION DAMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . RS . . . . 32 . . . . 33 . . . . 33 . . . . 33 . . . . 33 . . . . 34 . . . . 34 . . . . 34 . . . . 35 . . . . 35 . . . . 35 . . . . 35 . . . . 36 . . . . 36 . . . . 37 . . . . 37 . . . . 37 . . . . 38 . . . . 38 . . . . . . . . . . . . . 38 . 38 . 39 . 39 . . . . 41 . . . . 42 . . . . 43 . . . . 43 . . . . 44 . . . . . . . . . . . . . 45 . 45 . 45 . 46 . . . . 47 . . . . 48 . . . . 48 STRUCTURAL COLLAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . ENGINE MOUNTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . FRONT MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . LEFT MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . REAR MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . RIGHT MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . LUBRICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE . . . . . . . . . . . OIL STANDARD PROCEDURE ENGINE OIL LEVEL CHECK . . . . . . . . STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . OIL FILTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ..................... ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . INTAKE MANIFOLD DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS . . . . . . . . . . . . . . . . INTAKE MANIFOLD - UPPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ..................... INSTALLATION . . . . . . . . . . . . . . . . . . . . INTAKE MANIFOLD - LOWER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ..................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 . . . . . 49 . . . . . 49 . . . . . 49 . . . . . 50 . . . . . 50 . . . . . 50 . . . . . 51 . . . . . 51 . . . . . 52 . . . . . 52 . . . . . 53 . . . . . 53 . . . . . 53 . . . . . 53 . . . . . 54 . . . . . 54 . . . . . 54 . . . . . 55 . . . . . 55 . . . . . 55 . . . . . 55 . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . . . . 55 . 56 . 57 . 57 . 58 . 58 . . . . . 59 . . . . . 59 . . . . . 59 . . . . . 60 . . . . . 61 . . . . . 61 . . . . . 61 . . . . . 61 . . . . . 61 ENGINE 2.4L RS EXHAUST MANIFOLD DESCRIPTION . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . INSPECTION .............. INSTALLATION . . . . . . . . . . . . . TIMING BELT COVER(S) REMOVAL . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . TIMING BELT AND SPROCKET(S) REMOVAL REMOVAL - TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 . 62 . 62 . 62 . 62 . 62 . . . . . . . . . . . . 63 . . . . . . . . . . . . 63 . . . . . . . . . . . . 64 REMOVAL - CRANKSHAFT SPROCKET . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION - CRANKSHAFT SPROCKET INSTALLATION - TIMING BELT . . . . . . . . . TIMING BELT TENSIONER & PULLEY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . BALANCE SHAFTS AND CARRIER ASSEMBLY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2.4L DIAGNOSIS AND TESTING DESCRIPTION DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft with hydraulic lash adjusters and four valve per cylinder design. The engine is free-wheeling; meaning it has provisions for piston-to-valve clearance. However valve-tovalve interference can occur, if camshafts are rotated independently. The cylinders are numbered from front of the engine to the rear. The firing order is 1–3–4–2. The engine identification number is located on the rear of the cylinder block (Fig. 1). Fig. 1 Engine Identification 1 - ENGINE IDENTIFICATION LOCATION 9-3 . . 66 . . 66 . 66 . . 67 . . 68 . . 69 . . . . . 69 . 70 . 70 . 71 Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls). Refer to the Engine Mechanical and the Engine Performance diagnostic charts, for possible causes and corrections of malfunctions (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING - MECHANICAL) (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING - PERFORMANCE). For fuel system diagnosis, (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING). Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following: • Cylinder Compression Pressure Test • Cylinder Combustion Pressure Leakage Test • Engine Cylinder Head Gasket Failure Diagnosis • Intake Manifold Leakage Diagnosis • Hydraulic Lash Adjuster Noise Diagnosis • Engine Oil Leak Inspection 9-4 ENGINE 2.4L RS ENGINE 2.4L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION ENGINE WILL NOT START ENGINE STALLS OR IDLES ROUGH POSSIBLE CAUSE CORRECTION 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 ELECTRICAL/BATTERY SYSTEM DIAGNOSIS AND TESTING) 2. Corroded or loose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to terminals. 3. Faulty starter. 3. Test starting system. (Refer to 8 ELECTRICAL/STARTING DIAGNOSIS AND TESTING) 4. Faulty coil(s) or control unit. 4. Test and replace as needed. (Refer to Appropriate Diagnostic Information) 5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 ELECTRICAL/IGNITION CONTROL - SPECIFICATIONS) 6. Contamination in fuel system. 6. Clean system and replace fuel filter. 7. Faulty fuel pump. 7. Test fuel pump and replace as needed. (Refer to Appropriate Diagnostic Information) 8. Incorrect engine timing. 8. Check for a skipped timing belt/chain. 1. Idle speed too low. 1. Test minimum air flow. (Refer to Appropriate Diagnostic Information) 2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic Information) 3. Intake manifold leakage. 3. Inspect intake manifold, manifold gasket, and vacuum hoses. 4. Faulty ignition coil(s). 4. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) ENGINE 2.4L RS 9-5 ENGINE 2.4L (Continued) CONDITION ENGINE LOSS OF POWER ENGINE MISSES ON ACCELERATION ENGINE MISSES AT HIGH SPEED POSSIBLE CAUSE CORRECTION 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter. 3. Faulty fuel pump. 3. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 4. Incorrect valve timing. 4. Correct valve timing. 5. Leaking cylinder head gasket. 5. Replace cylinder head gasket. 6. Low compression. 6. Test compression of each cylinder. 7. Burned, warped, or pitted valves. 7. Replace valves. 8. Plugged or restricted exhaust system. 8. Perform exhaust restriction test. (Refer to 11 - EXHAUST SYSTEM DIAGNOSIS AND TESTING) Install new parts, as necessary. 9. Faulty ignition coil(s). 9. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 1. Dirty or incorrectly gapped spark plugs. 1. Clean spark plugs and set gap. 2. Contamination in Fuel System. 2. Clean fuel system and replace fuel filter. 3. Burned, warped, or pitted valves. 3. Replace valves. 4. Faulty ignition coil(s). 4. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap. 2. Faulty ignition coil(s). 2. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 3. Dirty fuel injector(s). 3. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 4. Contamination in fuel system. 4. Clean system and replace fuel filter. 9-6 ENGINE 2.4L RS ENGINE 2.4L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION NOISY VALVES POSSIBLE CAUSES CORRECTION 1. High or low oil level in crankcase. 1. Check and correct engine oil level. 2. Thin or diluted oil. 2. Change oil to correct viscosity. 3. Thick oil 3. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. CONNECTING ROD NOISE 4. Low oil pressure. 4. Check and correct engine oil pressure problem. 5. Dirt in hydraulic lifters/lash adjusters. 5. Replace hydraulic lifters/lash adjusters. 6. Worn rocker arms. 6. Inspect oil supply to rocker arms. 7. Worn hydraulic lifters/lash adjusters. 7. Replace hydraulic lifters/lash adjusters. 8. Worn valve guides. 8. Replace cylinder head assembly. 9. Excessive runout of valve seats on valve faces. 9. Grind valve seats and valves. 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Thin or diluted oil. 3. Change oil to correct viscosity. 4. Thick oil 4. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. 5. Excessive bearing clearance. 5. Measure bearings for correct clearance. Repair as necessary. 6. Connecting rod journal out-of-round. 6. Replace crankshaft or grind surface. 7. Misaligned connecting rods. 7. Replace bent connecting rods. ENGINE 2.4L RS 9-7 ENGINE 2.4L (Continued) CONDITION MAIN BEARING NOISE POSSIBLE CAUSES CORRECTION 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Thin or diluted oil. 3. Change oil to correct viscosity. 4. Thick oil 4. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. OIL PRESSURE DROP OIL LEAKS 5. Excessive bearing clearance. 5. Measure bearings for correct clearance. Repair as necessary. 6. Excessive end play. 6. Check thrust bearing for wear on flanges. 7. Crankshaft journal out-of-round or worn. 7. Replace crankshaft or grind journals. 8. Loose flywheel or torque converter. 8. Tighten to correct torque. 1. Low oil level. 1. Check engine oil level. 2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/ switch. 3. Low oil pressure. 3. Check oil pressure sensor/switch and main bearing oil clearance. 4. Clogged oil filter. 4. Install new oil filter. 5. Worn parts in oil pump. 5. Replace worn parts or pump. 6. Thin or diluted oil. 6. Change oil to correct viscosity. 7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean, or replace. 8. Oil pump suction tube loose. 8. Remove oil pan and install new tube or clean, if necessary. 9. Oil pump cover warped or cracked. 9. Install new oil pump. 10. Excessive bearing clearance. 10. Measure bearings for correct clearance. 1. Misaligned or deteriorated gaskets. 1. Replace gasket(s). 2. Loose fastener, broken or porous metal part. 2. Tighten, repair or replace the part. 3. Misaligned or deteriorated cup or threaded plug. 3. Replace as necessary. 9-8 ENGINE 2.4L RS ENGINE 2.4L (Continued) CONDITION OIL CONSUMPTION OR SPARK PLUGS FOULED POSSIBLE CAUSES CORRECTION 1. PCV system malfunction. 1. Check system and repair as necessary. (Refer to 25 EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new rings. 3. Carbon in oil ring slots. 3. Install new rings. 4. Rings fitted too tightly in grooves. 4. Remove rings and check grooves. If groove is not proper width, replace piston. 5. Worn valve guide(s). 5. Replace cylinder head assembly. 6. Valve stem seal(s) worn or damaged. 6. Replace seal(s). DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed: (1) Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak. (2) Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light. (3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair as necessary. (4) If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection. (5) If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows: • Disconnect the fresh air hose (make-up air) at the cylinder head cover and plug or cap the nipple on the cover. • Remove the PCV valve hose from the cylinder head cover. Cap or plug the PCV valve nipple on the cover. • Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure. • Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provides the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures. • If the leakage occurs at the crankshaft rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak. (6) If no leaks are detected, turn off the air supply. Remove the air hose, all plugs, and caps. Install the PCV valve and fresh air hose (make-up air). Proceed to next step. (7) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light. NOTE: If oil leakage is observed at the dipstick tube to block location; remove the tube, clean and reseal using MoparT Stud & Bearing Mount (press fit tube applications only), and for O-ring style tubes, remove tube and replace the O-ring seal. INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: (1) Disconnect the battery. (2) Raise the vehicle. RS ENGINE 2.4L 9-9 ENGINE 2.4L (Continued) (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area, remove transmission for further inspection. (a) Circular spray pattern generally indicates seal leakage or crankshaft damage. (b) Where leakage tends to run straight down, possible causes are a porous block, oil gallery cup plug, bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items. (4) If no leaks are detected, pressurize the crankcase as previously described. CAUTION: Do not exceed 20.6 kPa (3 psi). (5) If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. (6) For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. (7) After the oil leak root cause and appropriate corrective action have been identified, replace component(s) as necessary. DIAGNOSIS AND TESTING - 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 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. (4) Remove the Auto Shutdown (ASD) relay from the PDC. (5) Be sure throttle blade is fully open during the compression check. (6) Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0–500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRBIIIt. For Special Tool identification, (Refer to 9 - ENGINE - SPECIAL TOOLS). (7) Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. (8) Repeat the previous step for all remaining cylinders. (9) Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. (10) If one or more cylinders have abnormally low compression pressures, repeat the compression test. (11) 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. DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: • Exhaust and intake valve leaks (improper seating). • Leaks between adjacent cylinders or into water jacket. • Any causes for combustion/compression pressure loss. WARNING: DO NOT REMOVE THE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Check the coolant level and fill as required. DO NOT install the pressure cap. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF. Clean spark plug recesses with compressed air. Remove the spark plugs. Remove the oil filler cap. Remove the air cleaner. 9 - 10 ENGINE 2.4L RS ENGINE 2.4L (Continued) Calibrate the tester according to the manufacturer’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum, with 552 kPa (80 psi) recommended. Perform the test procedures on each cylinder according to the tester manufacturer’s instructions. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the coolant. All gauge pressure indications should be equal, with no more than 25% leakage per cylinder. FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder. STANDARD PROCEDURE STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug (Fig. 2). Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopart Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer. It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately. STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be repaired. Essentially, this repair consists of drilling out worn or damaged threads, tapping the hole with a special Heli-Coil Tap, (or equivalent) and installing an insert into the tapped hole. This brings the hole back to its original thread size. CAUTION: Be sure that the tapped holes maintain the original center line. Heli-Coil tools and inserts are readily available from automotive parts jobbers. STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur. Fig. 2 Core Hole Plug Removal 1 2 3 4 5 - CYLINDER BLOCK REMOVE PLUG WITH PLIERS STRIKE HERE WITH HAMMER DRIFT PUNCH CUP PLUG CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems. (1) Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of foreign material. (2) Remove negative battery cable. (3) Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure. (4) With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket. (5) Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other). (6) Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.) (7) Repair engine or components as necessary to prevent this problem from re-occurring. ENGINE 2.4L RS 9 - 11 ENGINE 2.4L (Continued) CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. (8) Install new spark plugs. (9) Drain engine oil and remove oil filter. (10) Install a new oil filter. (11) Fill engine with specified amount of approved oil. (12) Connect negative battery cable. (13) Start engine and check for any leaks. STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-inplace gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other. MOPARt ENGINE RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPARt ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPARt GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges. MOPARt BED PLATE SEALANT is a unique (green-in-color) anaerobic type gasket material that is specially made to seal the area between the bed- plate and cylinder block without disturbing the bearing clearance or alignment of these components. The material cures slowly in the absence of air when torqued between two metallic surfaces, and will rapidly cure when heat is applied. MOPARt GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multilayer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator. SEALER APPLICATION Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopart Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets. STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. Never use the following to clean gasket surfaces: • Metal scraper • Abrasive pad or paper to clean cylinder block and head • High speed power tool with an abrasive pad or a wire brush (Fig. 3) 9 - 12 ENGINE 2.4L RS ENGINE 2.4L (Continued) NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Only use the following for cleaning gasket surfaces: • Solvent or a commercially available gasket remover • Plastic or wood scraper (Fig. 3) • Drill motor with 3M Roloc™ Bristle Disc (white or yellow) (Fig. 3) CAUTION: Excessive pressure or high RPM (beyond the recommended speed), can damage the sealing surfaces. The mild (white, 120 grit) bristle disc is recommended. If necessary, the medium (yellow, 80 grit) bristle disc may be used on cast iron surfaces with care. Fig. 4 Plastigage Placed in Lower Shell—Typical 1 - PLASTIGAGE (3) Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. 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 9 - ENGINE - SPECIFICATIONS). Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. Fig. 3 Proper Tool Usage For Surface Preparation 1 - ABRASIVE PAD 2 - 3M ROLOC™ BRISTLE DISC 3 - PLASTIC/WOOD SCRAPER 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. REMOVAL - ENGINE ASSEMBLY STANDARD PROCEDURE - 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 across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 in.) off center and away from the oil holes (Fig. 4). (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. (1) Perform fuel pressure release procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE) (2) Disconnect battery negative cable. (3) Remove air cleaner housing and inlet tube. (4) Disconnect the fuel line from fuel rail. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES - STANDARD PROCEDURE) (5) Disconnect all vacuum hoses. (6) Drain cooling system. (Refer to 7 - COOLING STANDARD PROCEDURE) (7) Remove radiator fans. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - REMOVAL) (8) Remove radiator upper and lower hoses. ENGINE 2.4L RS 9 - 13 ENGINE 2.4L (Continued) NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the transaxle, damage to the inner wall of the hose will occur. To prevent prevent potential leakage, the cooler hoses must be cut off flush at the transaxle fitting, and a service cooler hose splice kit must be installed upon reassembly. (9) Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with fittings. Plug cooler lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly. (10) Disconnect transmission shift linkage and electrical connectors. (11) Disconnect throttle body linkage. (12) Disconnect engine wiring harness. (13) Disconnect heater hoses from heater (Fig. 5). (14) Discharge air conditioning system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE) (15) Hoist vehicle and remove front wheels and tires. (16) Remove accessory drive belt splash shield. (17) Remove accessory drive belts. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL) (18) Remove axle shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) (19) Drain engine oil and remove oil filter. (Refer to 9 - ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE) (20) Remove crossmember cradle plate (Fig. 6). (21) Disconnect exhaust pipe from manifold (Fig. 7). Fig. 5 HEATER HOSES - 2.4L 1 - HEATER HOSES TO HEATER 2 - BOLT - HEATER TUBE SUPPORT 3 - HEATER HOSE TO ENGINE - SUPPLY AND RETURN 9 - 14 ENGINE 2.4L RS ENGINE 2.4L (Continued) Fig. 6 Crossmember Cradle Plate 1 - CRADLE PLATE Fig. 7 Catalytic Converter to Exhaust Manifold 1 2 3 4 - CATALYTIC CONVERTER BOLT GASKET FLAG NUT (22) Remove engine front mount and bracket from engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/ FRONT MOUNT - REMOVAL) (23) Remove structural collar. (Refer to 9 ENGINE/ENGINE BLOCK/STRUCTURAL COVER REMOVAL) (24) Remove rear engine mount bracket. (Refer to 9 - ENGINE/ENGINE MOUNTING/REAR MOUNT REMOVAL) (25) Mark flex plate to torque converter and remove torque converter bolts. (26) Pinch-off power steering supply hose at pump. Remove hose from pump. (27) Remove and set aside the power steering pump and bracket. Do not disconnect pressure line. (28) Lower vehicle. (29) Remove A/C lines at compressor and cap openings. (30) Remove engine ground straps (strap at engine right mount and at starter). (31) Raise vehicle enough to allow engine dolly Special Tool 6135, cradle Special Tool 6710 with Posts Special Tool 6848 to be installed under vehicle (Fig. 8). (32) Loosen cradle posts to allow movement for proper positioning. Locate two rear posts (right side of engine) into the holes on the engine bedplate. Locate the two front posts (left side of engine) on the oil pan rails (Fig. 8). Lower vehicle and position cradle mounts until the engine is resting on mounts. Tighten mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission. (33) Install safety straps around the engine to cradle. Tighten straps and lock. (34) Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION are on the cradle. (35) Remove engine and transmission mount bolts. (36) Raise vehicle slowly. It may be necessary to move the engine/transmission assembly with the dolly to allow for removal around the body. ENGINE 2.4L RS ENGINE 2.4L (Continued) Fig. 8 Positioning Engine Cradle Support Post Mounts 1 - SPECIAL TOOL POSTS 6848 2 - SPECIAL TOOL 6135 DOLLY 3 - SPECIAL TOOL POSTS 6848 4 - SPECIAL TOOL 6710 CRADLE 5 - SPECIAL TOOL 6848 - POST CONTACT ON PAN RAIL 9 - 15 9 - 16 ENGINE 2.4L RS ENGINE 2.4L (Continued) INSTALLATION - ENGINE ASSEMBLY (1) Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission. (2) Align engine and transmission mounts to attaching points. Install mounting bolts at the right (Fig. 9) and left mounts (Fig. 10). Fig. 10 LEFT MOUNT TO FRAME BRACKET 1 2 3 4 Fig. 9 RIGHT MOUNT TO RAIL AND ENGINE 1 2 3 4 5 - BOLT - MOUNT TO RAIL 68 N·m (50 ft. lbs.) BOLT - MOUNT TO ENGINE 54 N·m (40 ft. lbs.) BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N·m (50 ft. lbs.) RIGHT ENGINE MOUNT RIGHT FRAME RAIL (3) Remove safety straps. (4) Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135 and 6710. (5) Install rear mount bracket and rear mount through bolt. (Refer to 9 - ENGINE/ENGINE MOUNTING/REAR MOUNT - INSTALLATION) (6) Install the flex plate to torque converter bolts. (7) Install structural collar. (Refer to 9 - ENGINE/ ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION) (8) Install front mount bracket and front mount through bolt. (Refer to 9 - ENGINE/ENGINE MOUNTING/FRONT MOUNT - INSTALLATION) (9) Connect exhaust system to manifold (Fig. 7). (10) Install crossmember cradle plate (Fig. 6). (11) Install new oil filter. (12) Install power steering pump and bracket. - FRAME BRACKET FRAME RAIL - LEFT BOLT TRANSAXLE MOUNT (13) Connect power steering supply line to pump and remove pinch-off pliers. (14) Connect A/C compressor hoses to compressor. (15) Install accessory drive belts. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION) (16) Install axle shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) (17) Install accessory drive belt splash shield. (18) Install front wheels and tires. (19) Remove plugs from transmission cooler hoses and install transaxle oil cooler line service splice kit. Refer to instructions included with kit. (20) Connect the transaxle shift linkage and electrical connectors. (21) Connect heater hoses (Fig. 5). (22) Install ground straps. (23) Connect all engine and throttle body electrical connections. (24) Connect all vacuum lines. (25) Connect the throttle cables. (26) Connect the fuel line. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) (27) Connect radiator lower and upper hoses. (28) Install radiator fans. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - INSTALLATION) (29) Fill cooling system. (Refer to 7 - COOLING STANDARD PROCEDURE) (30) Connect battery cables. (31) Install air cleaner and inlet hose. ENGINE 2.4L RS 9 - 17 ENGINE 2.4L (Continued) (32) Fill engine crankcase with proper oil to correct level. (33) Start engine and run until operating temperature is reached. (34) Adjust transmission linkage, if necessary. SPECIFICATIONS DESCRIPTION SPECIFICATION Piston Ring Groove Depth No. 1 4.640–4.784 mm (0.182–0.188 in.) Piston Ring Groove Depth No. 2 4.575–4.719 mm (0.180–0.185 in.) Piston Ring Groove Depth No. 3 SPECIFICATIONS - 2.4L ENGINE 4.097–4.236 mm (0.161–0.166 in.) Piston Pins DESCRIPTION SPECIFICATION Clearance in Piston 0.005–0.018 mm General Specification Type (0.0002–0.0008 in.) In-Line OHV, DOHC Number of Cylinders 4 Displacement 2.4 Liters Clearance in Connecting Rod Diameter 21.998–22.003 mm (0.8660–0.8662 in.) (148 cu. in.) Bore 87.5 mm (3.445 in.) Stroke End Play None Length 72.75–73.25 mm (2.864–2.883 in.) 101.0 mm (3.976 in.) Compression Ratio 9.4:1 Firing Order 1-3-4-2 Compression Pressure 690 kPa (Minimum) Interference Piston Rings Ring Gap—Top Compression Ring 0.25–0.51 mm (0.0098–0.020 in.) Wear Limit 0.8 mm (100 psi Minimum) Max. Variation Between Cylinders 25% Cylinder Block Cylinder Bore Diameter (0.031 in.) Ring Gap—2nd Compression Ring 0.23–0.48 mm (0.009–0.018 in.) Wear Limit 0.8 mm 87.4924–87.5076 mm (3.4446–3.4452 in.) Out-of-Round (Max.) 0.051 mm (0.002 in.) Taper (Max.) (0.031 in.) Ring Gap—Oil Control Steel Rails 0.25–0.64 mm (0.0098–0.025 in.) Wear Limit 1.0 mm 0.051 mm (0.002 in.) Pistons Piston Diameter 87.463–87.481 mm (0.039 in.) Ring Side Clearance— Compression Rings 0.030–0.080 mm (0.0011–0.0031 in.) Wear Limit 0.10 mm (0.004 in.) (3.4434–3.4441 in.) Clearance @ 14 mm (9/16 in.) from bottom of skirt Weight 0.024–0.057 mm (0.0009–0.0022 in.) 346–356 grams (12.20–12.56 oz.) Land Clearance (Diametrical) Piston Length 0.614–0.664 mm (0.024–0.026 in.) 66.25 mm (2.608 in.) Ring Side Clearance—Oil Ring Pack Ring Width— Compression Rings Ring Width—Oil Ring Pack 0.012–0.178 mm (0.0004–0.0070 in.) 1.47–1.50 mm (0.057–0.059 in.) 2.72–2.88 mm (0.107–0.1133 in.) Connecting Rod Bearing Clearance 0.025–0.071 mm (0.0009–0.0027 in.) 9 - 18 ENGINE 2.4L RS ENGINE 2.4L (Continued) DESCRIPTION SPECIFICATION Wear Limit 0.075 mm (0.003 in.) Bore Diameter—Piston Pin 20.96–20.98 mm (0.8252–0.8260 in.) Bore Diameter— Crankshaft End 53.007–52.993 mm (2.0868–2.0863 in.) Side Clearance DESCRIPTION Lift (Zero Lash) Intake Exhaust (0.259 in.) 0.40 mm Weight—Total (Less Bearing) 565.8 grams Main Bearing Journal Diameter 59.992–60.008 mm Journal Out-of-Round (Max.) 0.0035 mm (0.0003 in.) Journal Taper (Max.) 0.007 mm (1.968–1.9685 in.) 51° Opens (BTDC) 1° 232° Exhaust Valve Timing* Crankshaft 49.984–50.000 mm Closes (ABDC) Duration (19.96 oz.) Connecting Rod Journal Diameter 6.60 mm Intake Valve Timing* (0.005–0.015 in.) (0.016 in.) 8.25 mm (0.324 in.) 0.13–0.38 mm Wear Limit SPECIFICATION Closes (ATDC) 7° Opens (BBDC) 47° Duration 234° Valve Overlap 8° *All readings in crankshaft degrees. Timing points @ 4° from top of Ramps. (2.362–2.3625 in.) Cylinder Head Material Cast Aluminum Gasket Thickness (Compressed) 0.71 mm (0.028 in.) (0.0001 in.) End Play Valve Seat 0.09–0.24 mm (0.0035–0.0094 in.) Wear Limit 0.38 mm Angle 44.5–45° Seat Diameter—Intake (1.353–1.363 in.) (0.015 in.) Main Bearing Diametrical Clearance 0.018–0.062 mm Body Diameter 15.901–15.913 mm (0.626–0.6264 in.) Plunger Travel Minimum (Dry) 3.0 mm (0.118 in.) Cylinder Head Camshaft Bearing Bore Diameter Journals No.1–6 Seat Diameter—Exhaust Runout (Max.) Valve Seat Width—Intake and Exhaust 0.9–1.3 mm (0.035–0.051 in.) Service Limit—Intake 2.0 mm (0.079 in.) Service Limit—Exhaust 2.5 mm 26.020–26.041 mm Camshaft Journal Diameter No. 1–6 (0.098 in.) Valve Guide Diameter I.D. 25.951–25.970 mm (1.021–1.022 in.) End Play 0.05 mm (0.002 in.) (1.024–1.025 in.) Bearing Clearance— Diametrical 27.06–27.32 mm (1.065–1.075 in.) (0.0007–0.0024 in.) Hydraulic Lash Adjuster 34.37–34.63 mm Guide Bore Diameter 0.069–0.071 mm (0.0027–0.003 in.) 0.05–0.17 mm (0.0019–0.0066 in.) 5.975–6.000 mm (0.235–0.236 in.) 11.0–11.02 mm (0.4330–0.4338 in.) Guide Height (spring seat to guide tip) 13.25–13.75 mm (0.521–0.541 in.) ENGINE 2.4L RS 9 - 19 ENGINE 2.4L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Service Limit Valves Face Angle—Intake and Exhaust 44.5—45° Head Diameter—Intake 34.67–34.93 mm 0.25 mm (0.010 in.) Valve Springs Free Length (Approx.) 48.4 mm 1.364–1.375 in.) Head Diameter—Exhaust 28.32–28.52 mm (1.114–1.122 in.) Valve Length (Overall) —Intake 112.76–113.32 mm (4.439–4.461 in.) —Exhaust 110.89–111.69 mm (4.365–4.397 in.) Valve Stem Diameter —Intake (1.905 in.) Nominal Force (Valve Closed) (75.98 lbs. @ 1.496 in.) Nominal Force (Valve Open) (136 lbs. @ 1.172 in.) 607 N @ 29.75 mm Installed Height 38.00 mm (1.496 in.) Number of Coils 7.82 Wire Diameter 3.86 mm 5.934–5.952 mm (1.496 in.) (0.2337–0.2344 in.) —Exhaust 338 N @ 38.0 mm 5.906–5.924 mm (0.2326–0.2333 in.) Oil Pump Clearance Over Rotors (Max.) Valve Margin Intake (0.004 in.) 1.2–1.7 mm (0.047–0.066 in.) Service Limit 0.95 mm (1/32 in.) Exhaust Cover Out-of-Flat (Max.) (0.038–0.051 in.) 1.05 mm Inner Rotor Thickness (Min.) Intake Outer Rotor Thickness (Min.) Exhaust 47.99 mm Outer Rotor Clearance (Max.) Intake 0.048–0.066 mm Outer Rotor Diameter (Min.) 0.076 mm Tip Clearance Between Rotors (Max.) 0.25 mm (0.010 in.) Exhaust 0.0736–0.094 mm (0.0029–0.0037 in.) Max. Allowable 0.101 mm (0.004 in.) 0.20 mm (0.008 in.) Oil Pressure At Curb Idle Speed* (0.003 in.) Service Limit 79.95 mm (3.148 in.) (0.0018–0.0025 in.) Max. Allowable 0.039 mm (0.015 in.) (1.889 in.) Valve Stem to Guide Clearance 9.40 mm (0.370 in.) 48.04 mm (1.891 in.) 9.40 mm (0.370 in.) (3/64 in.) Valve Stem Tip Height 0.025 mm (0.001 in.) 0.985–1.315 mm Service Limit 0.10 mm 25 kPa (4 psi) At 3000 rpm 170–550 kPa (25–80 psi) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. 9 - 20 ENGINE 2.4L RS ENGINE 2.4L (Continued) SPECIFICATIONS - TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. N·m Ft. Lbs. In. Lbs. Exhaust Manifold to Cylinder Head—Bolts 19 — 170 Balance Shaft Carrier to Block—Bolts 54 40 — Exhaust Manifold Heat Shield—Bolts 12 — 105 Balance Shaft Gear Cover—Double Ended Fastener 12 — 105 Intake Manifold - Lower —Bolts 28 — 250 — 250 28 — 250 Intake Manifold Upper—Bolts 28 Balance Shaft Sprocket— Bolt Oil Filter 12 — 105 Balance Shaft Chain Tensioner—Bolts 12 — 105 Oil Pan—Bolts 12 — 105 Balance Shaft Carrier Cover—Bolts 12 — 105 Oil Pan Drain—Plug 27 20 — Oil Pressure Switch 21 — 190 Camshaft Sprocket—Bolt 101 75 — Oil Pump to Block—Bolts 28 — 250 27 +1⁄4 turn 20 +1⁄4 turn — Oil Pump Cover Plate—Bolts 12 — 105 Oil Pump Pick-up Tube—Bolt 28 20 — Oil Pump Relief Valve—Cap 41 30 — Spark Plugs 18 13 — DESCRIPTION Connecting Rod Cap—Bolts Crankshaft Main Bearing Cap/Bedplate —M8 Bolts 28 —M11 Bolts 41 + ⁄ Turn 30 +1⁄4 Turn — Crankshaft Damper 136 100 — Cylinder Head—Bolts (Refer to 9 - ENGINE/ CYLINDER HEAD INSTALLATION) 14 250 Cylinder Head Cover— Bolts 12 — 105 Flex Plate to Crankshaft 95 70 — Engine Mount Bracket Right—Bolts 61 45 — Engine Mounting—Bolts (Refer to 9 ENGINE/ ENGINE MOUNTING) Structural Collar (Refer to 9 - ENGINE/ ENGINE BLOCK/ STRUCTURAL COVER INSTALLATION) Timing Belt Covers - Front Covers to Rear Cover—Bolts 7 — 60 - Rear Cover—M6 Bolts 12 — 105 —M8 Bolts 28 — 250 61 45 — Timing Belt Tensioner Assembly—Bolts ENGINE 2.4L RS 9 - 21 ENGINE 2.4L (Continued) SPECIAL TOOLS 2.4L ENGINE Post Kit Engine Cradle 6848 Puller 1026 Camshaft Sprocket Holder 6847 Crankshaft Damper Removal Insert 6827A Camshaft Seal Remover C-4679A Dolly 6135 Camshaft Seal Installer MD-998306 Cradle 6710A Crankshaft Damper/Sprocket Installer 6792 9 - 22 ENGINE 2.4L RS ENGINE 2.4L (Continued) Indicator, Cylinder Bore C-119 Valve Spring Compressor 8215-A Connecting Rod Guides 8189 Adaptor 8436 Crankshaft Sprocket Remover 6793 Valve Spring Compressor MD998772A Crankshaft Sprocket Remover Insert C-4685-C2 Valve Spring Compressor Adapter 6779 Front Crankshaft Oil Seal Remover 6771 ENGINE 2.4L RS 9 - 23 ENGINE 2.4L (Continued) Front Crankshaft Oil Seal Installer 6780 Balance Shaft Sprocket Installer 6052 Combustion Leak Tester C-3685-A Oil Pressure Gauge C-3292 Adapter 8406 Pressure Transducer CH7059 Rear Crankshaft Oil Seal Installer 6926 Cylinder Compression Pressure Adaptor 8116 Driver Handle C-4171 DRB IIIT with PEP Module OT-CH6010A 9 - 24 ENGINE 2.4L RS AIR CLEANER ELEMENT REMOVAL (1) Unsnap 2 clips. (2) Lift cover and pull toward the engine and remove cover tabs from air box. (3) Lift cover and remove the element (Fig. 11). Fig. 12 IAT SENSOR 2.4L (2) Install bolt to hold air box to the upper radiator cross member. (3) Install the inlet hose to the throttle body. (4) Connect the inlet air temperature sensor (Fig. 12). (5) Connect the negative battery cable. CYLINDER HEAD DESCRIPTION AIR CLEANER HOUSING The cross flow designed, aluminum cylinder head contains dual over-head camshafts with four valves per cylinder (Fig. 13). The valves are arranged in two in-line banks. The intake valves face toward the front of the vehicle. The exhaust valves face the dash panel. The cylinder head incorporates powdered metal valve guides and seats. The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts. Integral oil galleries provide lubrication passages to the hydraulic lash adjusters, camshafts, and valve mechanisms. REMOVAL OPERATION (1) Disconnect the negative battery cable. (2) Disconnect the inlet air temperature sensor (Fig. 12). (3) Remove the inlet hose to throttle body (Fig. 11). (4) Remove the bolt for air box at upper radiator cross member. (5) Pull air box up and off over the single locating pin. (6) Remove air box from vehicle The cylinder head closes the combustion chamber, allowing the pistons to compress the fuel/air mixture for ignition. The valves are actuated by the lobe profiles on the camshaft to open and close at specified duration to either allow clean air in the combustion chamber or the exhaust gases out; depending on the stroke of the engine. Fig. 11 AIR BOX COVER INSTALLATION (1) Install the air filter element into air box (Fig. 11). (2) Move cover so that the tabs insert into the air box. (3) Push cover down and snap the 2 clips. INSTALLATION (1) Install air box into vehicle and onto the locating pin. DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. ENGINE 2.4L RS 9 - 25 CYLINDER HEAD (Continued) VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. COOLING SYSTEM TESTER METHOD WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident. Fig. 13 Cylinder Head and Camshafts 1 2 3 4 5 - CAMSHAFT BEARING CAPS PLUG CAMSHAFT CYLINDER HEAD CAMSHAFT OIL SEAL CHEMICAL TEST METHOD Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit. REMOVAL - CYLINDER HEAD Possible indications of the cylinder head gasket leaking between adjacent cylinders are: • Loss of engine power • Engine misfiring • Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: • Engine overheating • Loss of coolant • Excessive steam (white smoke) emitting from exhaust • Coolant foaming CYLINDER-TO-CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50–70% reduction in compression pressure. CYLINDER-TO-WATER JACKET LEAKAGE TEST WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP REMOVED. (1) Perform fuel system pressure release procedure before attempting any repairs. (Refer to 14 FUEL SYSTEM/FUEL DELIVERY - SPECIFICATIONS) (2) Disconnect battery negative cable. (3) Drain cooling system. (Refer to 7 - COOLING STANDARD PROCEDURE) (4) Remove air filter housing and inlet tube. (5) Remove upper intake manifold. (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL) (6) Remove heater tube support bracket from cylinder head. (7) Disconnect radiator upper and heater supply hoses from intake manifold water outlet connections. (8) Remove accessory drive belts. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL) (9) Raise vehicle and remove exhaust pipe from manifold. (10) Remove power steering pump reservoir and line support bracket from lower intake manifold and set aside. Do not disconnect lines. (11) Remove ignition coil and wires from engine. (12) Disconnect cam sensor and fuel injector wiring connectors. 9 - 26 ENGINE 2.4L RS CYLINDER HEAD (Continued) (13) Remove timing belt and camshaft sprockets. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (14) Remove timing belt idler pulley and rear timing belt cover. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) REMOVAL) (15) Remove cylinder head cover. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) (16) Remove camshafts (Refer to 9 - ENGINE/ CYLINDER HEAD/CAMSHAFT(S) - REMOVAL). NOTE: Identify rocker arm position to ensure correct re-installation in original position, if reused. (17) Remove rocker arms. (Refer to 9 - ENGINE/ CYLINDER HEAD/ROCKER ARMS - REMOVAL) (18) Remove cylinder head bolts in REVERSE sequence of tightening (Fig. 19). (19) Remove cylinder head from engine block. (20) Inspect and clean cylinder head. (Refer to 9 ENGINE/CYLINDER HEAD - INSPECTION) (Refer to 9 - ENGINE/CYLINDER HEAD - CLEANING) Fig. 14 Checking Cylinder Head Flatness 1 - FEELER GAUGE 2 - STRAIGHT EDGE CLEANING To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCEDURE). Be careful not to gouge or scratch the aluminum head sealing surface. Clean all engine oil passages. INSPECTION (1) Cylinder head must be flat within 0.1 mm (0.004 in.) (Fig. 14). (2) Inspect camshaft bearing journals for scoring. (3) Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. (4) Using a small hole gauge and a micrometer, measure valve guides in 3 places top, middle and bottom (Fig. 15). (Refer to 9 - ENGINE - SPECIFICATIONS) Replace guides if they are not within specification. (5) Check valve guide height (Fig. 16). Fig. 15 Checking Wear on Valve Guide—Typical 1 - TOP 2 - MIDDLE 3 - BOTTOM 4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT LOCATIONS INSTALLATION - CYLINDER HEAD NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts must be replaced (Fig. 17). Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced. (1) Before installing the bolts, the threads should be coated with engine oil. (2) Position cylinder head gasket on engine block (Fig. 18). (3) Install cylinder head on engine block. (4) Tighten the cylinder head bolts in the sequence shown in (Fig. 19). Using the 4 step torque turn method, tighten according to the following values: • First All to 34 N·m (25 ft. lbs.) ENGINE 2.4L RS 9 - 27 CYLINDER HEAD (Continued) • Second All to 68 N·m (50 ft. lbs.) • Third All to 68 N·m (50 ft. lbs.) CAUTION: Do not use a torque wrench for the following step. • Fourth Turn an additional 1/4 Turn, Fig. 16 Valve Guide Height 1 - VALVE GUIDE 2 - 13.25 - 13.75 MM (.521 - .541 IN.) 3 - SPRING SEAT Fig. 19 Cylinder Head Tightening Sequence Fig. 17 Checking Bolts for Stretching (Necking) 1 2 3 4 - STRETCHED BOLT THREADS ARE NOT STRAIGHT ON LINE THREADS ARE STRAIGHT ON LINE UNSTRETCHED BOLT Fig. 18 Cylinder Head Gasket Positioning 1 - PART NUMBER FACES UP 2 - NO. 1 CYLINDER (5) Install rocker arms. (Refer to 9 - ENGINE/ CYLINDER HEAD/ROCKER ARMS - INSTALLATION) (6) Install camshafts. (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - INSTALLATION). (7) Install cylinder head cover. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) (8) Install timing belt rear cover and timing belt idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT / CHAIN COVER(S) - INSTALLATION) (9) Install timing belt and camshaft sprockets. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) (10) Connect cam sensor and fuel injectors wiring connectors. (11) Install ignition coil and wires. Connect ignition coil wiring connector. (12) Install power steering pump reservoir and line support bracket to cylinder head. (13) Raise vehicle and install the exhaust pipe to the manifold. (14) Install accessory drive belts. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION) (15) Install heater tube support bracket to cylinder head. (16) Connect radiator upper and heater hoses to intake manifold water outlet connections. (17) Install upper intake manifold. (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD INSTALLATION) (18) Using new gaskets, install EGR tube and tighten fasteners to 11 N·m (95 in. lbs.). 9 - 28 ENGINE 2.4L RS CYLINDER HEAD (Continued) (19) Install air inlet tube and housing. (20) Connect all vacuum lines, electrical wiring, ground straps and fuel line. (21) Fill cooling system. (Refer to 7 - COOLING STANDARD PROCEDURE) (22) Connect battery negative cable. CAMSHAFT OIL SEAL(S) REMOVAL (1) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS REMOVAL). (2) Hold each camshaft sprocket with Special Tool 6847 while removing center bolt (Fig. 20). (3) Remove camshaft sprockets. (4) Remove rear timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL). (5) Remove camshaft seal using Special Tool C-4679A (Fig. 21). Fig. 21 Camshaft Oil Seal - Removal With C-4679A 1 - SPECIAL TOOL C-4679 Fig. 22 Camshaft Seal - Installation 1 - SPECIAL TOOL MD-998306 Fig. 20 Camshaft Sprocket - Removal/Installation 1 - SPECIAL TOOL 6847 CAUTION: Do not nick shaft seal surface or seal bore. INSTALLATION (1) Shaft seal surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. (2) Install camshaft seals into cylinder head using Special Tool MD-998306 until flush with head (Fig. 22). (3) Install timing belt rear cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION). (4) Install camshaft sprockets. Hold each sprocket with Special Tool 6847 and tighten center bolt to 101 N·m (75 ft. lbs.) (Fig. 20). (5) Install timing belt and front covers (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION) (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION). ENGINE 2.4L RS CAMSHAFT(S) DESCRIPTION Both camshafts have six bearing journal surfaces and two cam lobes per cylinder (Fig. 23). Flanges at the rear journals control camshaft end play. Provision for a cam position sensor is located on the intake camshaft on the rear of the cylinder head. A hydrodynamic oil seal is used for oil control at the front of the camshaft. 9 - 29 (5) Record reading on dial indicator. For end play specification, (Refer to 9 - ENGINE - SPECIFICATIONS). (6) If end play is excessive, check cylinder head and camshaft for wear; replace as necessary. Fig. 24 Camshaft End Play - Typical REMOVAL OPERATION (1) Remove cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - REMOVAL). (2) Remove camshaft position sensor and camshaft target magnet (Refer to 8 - ELECTRICAL/IGNITION CONTROL/CAMSHAFT POSITION SENSOR REMOVAL). (3) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS REMOVAL). (4) Remove camshaft sprockets and timing belt rear cover (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT COVER(S) - REMOVAL). (5) Bearing caps are identified for location. Remove the outside bearing caps first (Fig. 25). (6) Loosen the camshaft bearing cap attaching fasteners in sequence shown (Fig. 26) one camshaft at a time. The camshaft is driven by the crankshaft via drive sprockets and belt. The camshaft has precisely machined lobes to provide accurate valve timing and duration. CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is wider. STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY (7) Identify the camshafts before removing from the head. The camshafts are not interchangeable. (8) Remove camshafts from cylinder head. Fig. 23 Camshafts 1 2 3 4 5 - CAMSHAFT BEARING CAPS PLUG CAMSHAFT CYLINDER HEAD CAMSHAFT OIL SEAL (1) Oil camshaft journals and install camshaft WITHOUT rocker arms. Install rear cam caps and tighten screws to specified torque. (2) Using a suitable tool, move camshaft as far rearward as it will go. (3) Zero dial indicator (Fig. 24). (4) Move camshaft as far forward as it will go. NOTE: If removing rocker arms, identify for reinstallation in the original position. CLEANING Clean camshaft with a suitable solvent. 9 - 30 ENGINE 2.4L RS CAMSHAFT(S) (Continued) Fig. 25 Camshaft Bearing Cap Identification Fig. 27 Checking Camshaft(s) for Wear 1 2 3 4 5 Fig. 26 Camshaft Bearing Cap - Removal 1 - REMOVE OUTSIDE BEARING CAPS FIRST - UNWORN AREA - ACTUAL WEAR - BEARING JOURNAL - LOBE - WEAR ZONE (1) Lubricate all camshaft bearing journals, rocker arms and camshaft lobes. (2) Install all rocker arms in original positions, if reused. (3) Position camshafts on cylinder head bearing journals. Install right and left camshaft bearing caps No. 2 – 5 and right No. 6. Tighten M6 fasteners to 12 N·m (105 in. lbs.) in sequence shown in (Fig. 28). (4) Apply Mopart Gasket Maker to No. 1 and No. 6 bearing caps (Fig. 29). Install bearing caps and tighten M8 fasteners to 28 N·m (250 in. lbs.). INSPECTION (1) Inspect camshaft bearing journals for damage and binding (Fig. 27). If journals are binding, 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 rocker arms. (3) Measure the lobe actual wear (unworn area wear zone = actual wear) (Fig. 27) and replace camshaft if out of limit. Standard value is 0.0254 mm (0.001 in.), wear limit is 0.254 mm (0.010 in.). INSTALLATION CAUTION: Ensure that NONE of the pistons are at top dead center when installing the camshafts. Fig. 28 Camshaft Bearing Cap Tightening Sequence NOTE: Bearing end caps must be installed before seals can be installed. (5) Install camshaft oil seals (Refer to 9 ENGINE/CYLINDER HEAD/CAMSHAFT OIL SEAL(S) - INSTALLATION). (6) Install camshaft target magnet and camshaft position sensor. ENGINE 2.4L RS 9 - 31 CAMSHAFT(S) (Continued) (1) Install new cylinder head cover gaskets and spark plug well seals (Fig. 30). Fig. 29 Camshaft Bearing Cap Sealing 1 - 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET MAKER (7) Install cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION). (8) Install timing belt rear cover and camshaft sprockets (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT COVER(S) - INSTALLATION). (9) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS INSTALLATION). CYLINDER HEAD COVER REMOVAL (1) Remove upper intake manifold. (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL) (2) Remove upper manifold support bracket. (3) Remove ignition coil and spark plug wires. (4) Disconnect PCV and make-up air hoses from cylinder head cover. (5) Remove cylinder head cover bolts. (6) Remove cylinder head cover from cylinder head. CLEANING Clean cylinder head and cover mating surfaces using a suitable solvent. INSPECTION Inspect cover rails for flatness. INSTALLATION NOTE: Replace spark plug well seals and bolt assemblies when installing a new cylinder head cover gasket. Fig. 30 Spark Plug Well Seals (2) Replace cylinder head cover bolt assemblies. CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. (3) Apply Mopart Engine RTV GEN II at the camshaft cap corners and at the top edges of the 1/2 round seal (Fig. 31). (4) Install cylinder head cover assembly to cylinder head. Install all bolts, ensuring the single (1) stud used to attach the upper intake manifold support bracket is located in the #8 location as shown in torque sequence diagram (Fig. 32). Tighten bolts in sequence shown in (Fig. 32). Using a 3 step torque method as follows: (a) Tighten all bolts to 4.5 N·m (40 in. lbs.). (b) Tighten all bolts to 9.0 N·m (80 in. lbs.). (c) Tighten all bolts to 12 N·m (105 in. lbs.). (5) Install ignition coil and spark plug wires. Tighten fasteners to 12 N·m (105 in. lbs.). (6) If the PCV valve was removed, apply Mopart Thread Sealant with Teflon to threads and install valve to cylinder head cover. Tighten PCV valve to 8 N·m (70 in. lbs.). (7) Connect PCV and make-up air hoses to cylinder head cover. (8) Install upper intake manifold. (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD INSTALLATION) 9 - 32 ENGINE 2.4L RS CYLINDER HEAD COVER (Continued) INTAKE/EXHAUST VALVES & SEATS DESCRIPTION The valves are made of heat resistant steel. They have chrome plated stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats. The valves have three-bead lock keepers to retain springs and to promote valve rotation. CLEANING (1) Clean all valves thoroughly burned, warped and cracked valves. and discard VALVE SPRINGS & SEALS REMOVAL REMOVAL - CYLINDER HEAD ON Fig. 31 Sealer Locations 1 – SEALER LOCATION (1) Remove cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). (2) Remove camshafts (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - REMOVAL). (3) Rotate crankshaft until piston is at TDC on compression. (4) With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure. (5) Using Special Tool MD-998772-A with adapter 6779 (Fig. 33), compress valve springs and remove valve locks. (6) Remove valve spring(s). (7) Remove valve stem seal(s) by a using valve stem seal tool (Fig. 35). Fig. 32 Cylinder Head Cover Tightening Sequence (Typical Cover Shown) Fig. 33 Valve Spring - Removal/Installation 1 - VALVE SPRING COMPRESSOR MD 998772A 2 - AIR HOSE ENGINE 2.4L RS 9 - 33 VALVE SPRINGS & SEALS (Continued) REMOVAL - CYLINDER HEAD OFF (1) With cylinder head removed from cylinder block, compress valve springs using a universal valve spring compressor. (2) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. (3) 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. (4) Inspect the valves. (Refer to 9 - ENGINE/CYLINDER HEAD/VALVE SPRINGS - INSPECTION) INSPECTION (1) Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct tension. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: • Valve Closed Nominal Tension—76 lbs. @ 38.0 mm (1.50 in.) • Valve Open Nominal Tension—136 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. Fig. 34 Valve Stem Seal/Valve Spring Seat 1 2 3 4 - VALVE VALVE VALVE VALVE RETAINING LOCKS SPRING SEAL AND VALVE SPRING SEAT ASSEMBLY SPRING RETAINER CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves. INSTALLATION INSTALLATION - CYLINDER HEAD ON (1) Install valve seal/valve spring seat assembly (Fig. 34). Push the assembly down to seat it onto the valve guide. (2) Install valve spring and retainer, use Special Tool MD-998772-A with adapter 6779 to compress valve springs only enough to install locks (Fig. 33). Correct alignment of tool is necessary to avoid nicking valve stems. (3) Remove air hose and install spark plugs. (4) Install camshafts (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - INSTALLATION). (5) Install cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION). INSTALLATION - CYLINDER HEAD OFF (1) Coat valve stems with clean engine oil and insert in cylinder head. (2) Install new valve stem seals on all valves using a valve stem seal tool (Fig. 35). The valve stem seals should be pushed firmly and squarely over valve guide. Fig. 35 Valve Stem Oil Seal Tool 1 - VALVE SEAL TOOL 2 - VALVE STEM (3) Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Ensure both locks are in the correct location after removing tool. 9 - 34 ENGINE 2.4L RS VALVE SPRINGS & SEALS (Continued) (4) Check the valve spring installed height B after refacing the valve and seat (Fig. 36). 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. a. Check lash adjusters for sponginess while installed in cylinder head. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. b. Remove suspected lash adjusters, and replace as necessary. REMOVAL NOTE: This procedure is for in-vehicle service with camshafts installed. Fig. 36 Checking Spring Installed Height and Valve Tip Height Dimensions 1 - GARTER SPRING 2 - VALVE SPRING SEAT 3 - CYLINDER HEAD SURFACE (1) Remove cylinder head cover. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) (2) Remove rocker arm. (Refer to 9 - ENGINE/ CYLINDER HEAD/ROCKER ARMS - REMOVAL) (3) Remove hydraulic lash adjuster (Fig. 37). (4) Repeat removal procedure for each hydraulic lash adjuster. (5) If reusing, mark each hydraulic lash adjuster for reassembly in original position. Lash adjusters are serviced as an assembly. HYDRAULIC LASH ADJUSTERS DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS A tappet-like noise may be produced from several items. Check the following items. (1) Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy. (2) Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour may be required. (3) During this time, turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature. (4) Low oil pressure. (5) The oil restrictor (integral to the head gasket) in the vertical oil passage to the cylinder head is plugged with debris. (6) Air ingested into oil due to broken or cracked oil pump pick up. (7) Worn valve guides. (8) Rocker arm ears contacting valve spring retainer. (9) Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system. (10) Faulty lash adjuster. Fig. 37 Hydraulic Lash Adjuster INSTALLATION (1) Install hydraulic lash adjuster (Fig. 37). Ensure the lash adjusters are at least partially full of engine oil. This is indicated by little or no plunger travel when the lifter is depressed. (2) Install rocker arm. (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS - INSTALLATION) (3) Repeat installation procedure for each hydraulic lash adjuster. (4) Install cylinder head cover. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) ENGINE 2.4L RS 9 - 35 ROCKER ARMS INSPECTION REMOVAL Inspect the rocker arm for wear or damage (Fig. 39). Replace as necessary. NOTE: This procedure is for in-vehicle service with camshafts installed. (1) Remove cylinder head cover. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) (2) Remove spark plugs. (3) Rotate engine until the camshaft lobe, on the follower being removed, is positioned on its base circle (heel). Also, the piston should be a minimum of 6.3 mm (0.25 in) below TDC position. CAUTION: If cam follower assemblies are to be reused, always mark position for reassembly in their original positions. (4) Using Special Tools 8215A and 8436 slowly depress valve assembly until rocker arm can be removed (Fig. 38). (5) Repeat removal procedure for each rocker arm. Fig. 39 Rocker Arm 1 - TIP 2 - LASH ADJUSTER POCKET 3 - ROLLER INSTALLATION (1) Lubricate rocker arm with clean engine oil. (2) Using Special Tools 8215A and 8436 slowly depress valve assembly until rocker arm can be installed on the hydraulic lifter and valve stem (Fig. 38). (3) Repeat installation procedure for each rocker arm. (4) Install spark plugs. (5) Install cylinder head cover. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) ENGINE BLOCK DESCRIPTION The cast iron cylinder block is a two-piece assembly, consisting of the cylinder block and bedplate (Fig. 40). The bedplate incorporates the main bearing caps and bolts to the cylinder block. This design offers a much stronger lower end and increased cylinder block rigidity. The rear oil seal retainer is integral with the block. The bedplate and block are serviced as an assembly. Fig. 38 Rocker Arm - Removal/Installation 1 - SPECIAL TOOL 8215A 2 - SPECIAL TOOL 8436 3 - 3/89 DRIVE RACHET 9 - 36 ENGINE 2.4L RS ENGINE BLOCK (Continued) Fig. 40 Cylinder Block and Bedplate 1 - CYLINDER BLOCK 2 - BEDPLATE STANDARD PROCEDURE STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin about 14 mm (9/16 inch.) from the bottom of the skirt as shown in (Fig. 42). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in (Fig. 41). Refer to for Engine Specifications (Refer to 9 - ENGINE - SPECIFICATIONS). Correct piston to bore clearance must be established in order to assure quiet and economical operation. Fig. 41 Checking Cylinder Bore NOTE: Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). STANDARD PROCEDURE - CYLINDER BORE HONING (1) Used carefully, the cylinder bore resizing hone, recommended tool C-823 or equivalent, equipped with 220 grit stones, is the best tool for this honing procedure. In addition to deglazing, it will reduce taper and out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes will clean up a bore and maintain the required limits. (2) Deglazing of the cylinder walls may be done using a cylinder surfacing hone, recommended tool C-3501 or equivalent, equipped with 280 grit stones, if the cylinder bore is straight and round. 20–60 strokes depending on the bore condition, will be sufficient to provide a satisfactory surface. Use a light honing oil. Do not use engine or transmission oil, mineral spirits or kerosene. Inspect cylinder walls after each 20 strokes. Fig. 42 Piston Measurement (3) Honing should be done by moving the hone up and down fast enough to get a cross-hatch pattern. When hone marks intersect at 40-60 degrees, the cross hatch angle is most satisfactory for proper seating of rings (Fig. 43). (4) A controlled hone motor speed between 200–300 RPM is necessary to obtain the proper crosshatch angle. The number of up and down strokes per minute can be regulated to get the desired 40–60 degree angle. Faster up and down strokes increase the cross-hatch angle. (5) After honing, it is necessary that the block be cleaned again to remove all traces of abrasive. ENGINE 2.4L RS 9 - 37 ENGINE BLOCK (Continued) The cylinder walls should be checked for out-ofround and taper with Tool C119 or equivalent (Fig. 44) (Refer to 9 - ENGINE - SPECIFICATIONS). If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted. Fig. 43 Cylinder Bore Cross-Hatch Pattern 1 - CROSS-HATCH PATTERN 2 - 40°–60° CAUTION: Ensure all abrasives are removed from engine parts after honing. It is recommended that a solution of soap and hot water be used with a brush and the parts then thoroughly dried. The bore can be considered clean when it can be wiped clean with a white cloth and cloth remains clean. Oil the bores after cleaning to prevent rusting. CLEANING Clean cylinder block thoroughly using a suitable cleaning solvent. INSPECTION ENGINE BLOCK (1) Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. (2) If new core plugs are to be installed, (Refer to 9 - ENGINE - STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS). (3) Examine block and cylinder bores for cracks or fractures. (4) Check block deck surfaces for flatness. Deck surface must be within service limit of 0.1 mm (0.004 in.). CYLINDER BORE NOTE: The cylinder bores should be measured at normal room temperature, 21°C (70°F). Fig. 44 Checking Cylinder Bore Size Measure the cylinder bore at three levels in directions A and B (Fig. 44). Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. (Refer to 9 - ENGINE - SPECIFICATIONS). CONNECTING ROD BEARINGS STANDARD PROCEDURE CONNECTING ROD - FITTING (1) For measuring connecting rod bearing clearance procedure and use of Plastigage(Refer to 9 ENGINE - STANDARD PROCEDURE). For bearing clearance refer to Engine Specifications. (Refer to 9 ENGINE - SPECIFICATIONS) NOTE: The rod bearing bolts should not be reused. (2) Before installing the NEW bolts the threads should be oiled with clean engine oil. (3) Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. 9 - 38 ENGINE 2.4L RS CONNECTING ROD BEARINGS (Continued) (4) Tighten the bolts to 27 N·m PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn) Do not use a torque wrench for last step. (5) Using a feeler gauge, check connecting rod side clearance (Fig. 45). Refer to clearance specifications (Refer to 9 - ENGINE - SPECIFICATIONS). Fig. 46 Crankshaft - Typical Fig. 45 Connecting Rod Side Clearance 1 - MAIN BEARING JOURNALS 2 - COUNTER BALANCE WEIGHTS CRANKSHAFT DESCRIPTION The crankshaft is made of nodular cast iron and includes five main bearing journals and four connecting rod journals (Fig. 46). The number three journal is the location for the thrust bearing. The mains and connecting rod journals have undercut fillet radiuses that are rolled for added strength. To optimize bearing loading, eight counterweights are used. OPERATION The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate. STANDARD PROCEDURE - CRANKSHAFT END PLAY (1) Using Dial Indicator C-3339 and Mounting Post L-4438, attach to front of engine, locating probe perpendicular on nose of crankshaft (Fig. 47). (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. Refer to Engine Specifications. REMOVAL NOTE: Crankshaft can not be removed when engine is in vehicle. Fig. 47 CHECKING CRANKSHAFT END PLAY (1) Remove engine assembly from vehicle. (Refer to 9 - ENGINE - REMOVAL) (2) Separate engine from transaxle. (3) Remove flex plate and crankshaft rear oil seal. (4) Mount engine on a repair stand. (5) Drain engine oil and remove oil filter. (6) Remove the oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL) (7) Remove engine mount support bracket. (8) Remove the crankshaft damper and timing belt covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (9) Remove the timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) ENGINE 2.4L RS 9 - 39 CRANKSHAFT (Continued) (10) Remove the crankshaft sprocket and oil pump. (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP REMOVAL) (11) Remove balance shafts and housing assembly. (Refer to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT - REMOVAL) NOTE: If piston/connecting rod replacement is necessary, remove cylinder head. (12) Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. should within specitifications. (Refer to 9 - ENGINE SPECIFICATIONS) Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter. DO NOT grind thrust faces of No. 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the nodular cast iron crankshafts, it is important that the final paper or cloth polish be in the same direction as normal rotation in the engine. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur. (13) Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts. (14) Remove all bedplate bolts from the engine block (Fig. 48). (15) Using a mallet gently tap the bedplate loose from the engine block dowel pins. CAUTION: Do not pry up on one side of the bedplate. Damage may occur to cylinder block to bedplate alignment and thrust bearing. (16) Bedplate should be removed evenly from the cylinder block dowel pins to prevent damage to the dowel pins and thrust bearing. (17) Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft. Fig. 48 Bedplate Bolt Tightenening Sequence INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 49). Limits of taper or out of round on any crankshaft journals Fig. 49 Crankshaft Journal Measurements INSTALLATION (1) Install the main bearing upper shells with the lubrication groove in the cylinder block (Fig. 50). Fig. 50 Installing Main Bearing Upper Shell 1 - LUBRICATION GROOVES 2 - OIL HOLES 9 - 40 ENGINE 2.4L RS CRANKSHAFT (Continued) (2) Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. CAUTION: Do not get oil on the bedplate mating surface. It will affect the sealer ability to seal the bedplate to cylinder block. (3) Oil the bearings and journals. Install crankshaft. CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. (4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of Mopart Bed Plate Sealant to cylinder block as shown in (Fig. 51). (7) Install main bearing bedplate to engine block bolts 11, 17, and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block. (8) 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 (NOT BED PLATE) and the rear crankshaft counterweight. This will hold the crankshaft in it’s furthest forward position. • Step 5: Install and tighten bolts (1–10) in sequence shown in (Fig. 52) to 41 N·m (30 ft. lbs.). • Step 6: Remove wedge tool used to hold crankshaft. (9) Tighten bolts (1–10) again to 41 N·m (30 ft. lbs.) in sequence shown in (Fig. 52). CAUTION: Do Not use a torque wrench for the following step. Fig. 51 Bedplate Sealing Fig. 52 Bedplate Bolt Torque Sequence (5) Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block. (6) Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil. (10) Turn bolts (1–10) an additional 1/4 turn in sequence shown in (Fig. 52). (11) Install main bearing bedplate to engine block bolts (11–20), and torque each bolt to 28 N·m (250 in. lbs.) in sequence shown in (Fig. 52). (12) Tighten bolts (11–20) again to 28 N·m (250 in. lbs.) in sequence shown in (Fig. 52). (13) After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 N·m (50 in. lbs.). (14) Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Torque connecting rod bolts to 27 N·m (20 ft. lbs.) plus 1/4 turn. (15) Install balance shafts and housing assembly. (Refer to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT - INSTALLATION) (16) Install the oil pump. (Refer to 9 - ENGINE/ LUBRICATION/OIL PUMP - INSTALLATION) (17) Install cylinder head if it was removed (Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION). (18) Install the timing belt rear cover. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (19) Install crankshaft sprocket (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION). (20) Install the timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) ENGINE 2.4L RS 9 - 41 CRANKSHAFT (Continued) (21) Install the timing belt front covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (22) Install engine mount support bracket. (23) Install the oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION) (24) Install the oil filter. (25) Install crankshaft rear oil seal. (Refer to 9 ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - INSTALLATION) (26) Install flex plate. Apply Mopart Lock & Seal Adhesive to bolt threads and tighten to 95 N·m (70 ft. lbs.). (27) Attach transaxle to engine. Tighten attaching bolts to 101 N·m (75 ft. lbs.). (28) Install the engine assembly. (Refer to 9 ENGINE - INSTALLATION) CRANKSHAFT MAIN BEARINGS Fig. 53 Main Bearing Identification 1 - OIL GROOVE 2 - MAIN BEARINGS 3 - OIL HOLE STANDARD PROCEDURE - MAIN BEARING FITTING For crankshaft specifications (Refer to 9 - ENGINE - SPECIFICATIONS). CRANKSHAFT MAIN BEARINGS The crankshaft is supported in five main bearings. All upper and lower bearing shells in the crankcase have oil grooves. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal (Fig. 53). Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 53). All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersized: 0.025 mm (0.001 in.) and 0.250 mm (0.010 in.). Never install an undersize bearing that will reduce clearance below specifications. Replace or machine the crankshaft as necessary to obtain proper bearing clearances. MAIN BEARING INSTALLATION (1) Install the main bearing shells with the lubrication groove in the cylinder block (Fig. 54). (2) Make certain oil holes in block line up with oil holes in bearings. Bearing tabs must seat in the block tab slots. CAUTION: Do not get oil on the bedplate mating surface. It will may effect the sealer ability to seal the bedplate to cylinder block. Fig. 54 Installing Main Bearing Upper Shell 1 - LUBRICATION GROOVES 2 - OIL HOLES (3) Oil the bearings and journals and install crankshaft. CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. Ensure that both cylinder block and bedplate surfaces are clean. (4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of anaerobic sealer Mopart Bed Plate Sealant to cylinder block as shown in (Fig. 55). (5) Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. 9 - 42 ENGINE 2.4L RS CRANKSHAFT MAIN BEARINGS (Continued) • Step 6: Remove wedge tool used to hold crankshaft. (10) Tighten bolts (1–10) again to 41 N·m (30 ft. lbs.) in sequence shown in (Fig. 56). CAUTION: Do Not use a torque wrench for the following step. Fig. 55 Main Bearing Caps/Bedplate Sealing (11) Turn bolts (1–10) an additional 1/4 turn in sequence shown in (Fig. 56). (12) Install main bearing bedplate to engine block bolts (11–20), and torque each bolt to 28 N·m (250 in. lbs.) in sequence shown in (Fig. 56). (13) Tighten bolts (11–20) again to 28 N·m (250 in. lbs.) in sequence shown in (Fig. 56). (14) After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 N·m (50 in. lbs.). CRANKSHAFT OIL SEAL FRONT REMOVAL Fig. 56 Main Bearing Caps/Bedplate Tightening Sequence (6) Position the main bearing/bedplate onto the engine block. (7) Before installing bolts, lubricate the threads with clean engine oil, wipe off any excess oil. (8) Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block. (9) 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 (NOT BED PLATE) and the rear crankshaft counterweight. This will hold the crankshaft in it’s furthest forward position. • Step 5: Install and tighten bolts (1–10) in sequence shown in (Fig. 56) to 41 N·m (30 ft. lbs.). (1) Remove the crankshaft vibration damper. (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) (2) Remove timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (3) Remove crankshaft sprocket using Special Tool 6793 and insert C-4685-C2 (Fig. 57). CAUTION: Do not nick shaft seal surface or seal bore. Fig. 57 Crankshaft Sprocket - Removal 1 - SPECIAL TOOL 6793 2 - CRANKSHAFT SPROCKET ENGINE 2.4L RS 9 - 43 CRANKSHAFT OIL SEAL - FRONT (Continued) (4) Using Tool 6771 to remove front crankshaft oil seal (Fig. 58). Be careful not to damage the seal surface of cover. Fig. 58 Front Crankshaft Oil Seal - Removal 1 - SPECIAL TOOL 6771 2 - REAR TIMING BELT COVER INSTALLATION (1) Install new seal by using Special Tool 6780 (Fig. 59). (2) Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. (3) Install crankshaft sprocket using Special Tool 6792 (Fig. 60). (4) Install timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) (5) Install crankshaft vibration damper. (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER INSTALLATION) Fig. 59 Crankshaft Front Oil Seal - Installation 1 - PROTECTOR 2 - SEAL 3 - SPECIAL TOOL 6780 CRANKSHAFT OIL SEAL REAR REMOVAL (1) Remove transaxle. Refer to TRANSMISSION/ TRANSAXLE - REMOVAL for procedure. (2) Remove flex plate. (3) Insert a 3/16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver (Fig. 61)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. Fig. 60 Crankshaft Sprocket - Installation 1 - SPECIAL TOOL 6792 2 - TIGHTEN NUT TO INSTALL 9 - 44 ENGINE 2.4L RS CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 62 Rear Crankshaft Seal and Special Tool 6926-1 Fig. 61 Rear Crankshaft Oil Seal—Removal 1 2 3 4 5 6 7 8 9 - REAR CRANKSHAFT SEAL ENGINE BLOCK ENGINE BLOCK REAR CRANKSHAFT SEAL METAL CASE PRY IN THIS DIRECTION CRANKSHAFT SCREWDRIVER REAR CRANKSHAFT SEAL DUST LIP SCREWDRIVER 1 - SPECIAL TOOL 6926–1 PILOT 2 - SEAL INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. NOTE: When installing seal, no lube on seal is needed. (1) Place Special Tool 6926-1 Seal Guide on crankshaft (Fig. 62). (2) Position seal over guide tool (Fig. 62). Guide tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation. CAUTION: If the seal is driven into the block past flush, this may cause an oil leak. (3) Drive the seal into the block using Special Tool 6926-2 and handle C-4171 (Fig. 63) until the tool bottoms out against the block (Fig. 64). Fig. 63 Crankshaft Seal and Special Tools 6926-2 & C-4171 1 2 3 4 - SPECIAL TOOL 6926–1 PILOT SEAL SPECIAL TOOL 6926–2 INSTALLER SPECIAL TOOL C-4171 ENGINE 2.4L RS 9 - 45 CRANKSHAFT OIL SEAL - REAR (Continued) REMOVAL Fig. 65 Piston Markings 1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA NOTE: Cylinder Head must be removed before Pistons and Rods (Refer to 9 - ENGINE/CYLINDER HEAD - REMOVAL). Fig. 64 Rear Crankshaft Seal—Installation 1 - SPECIAL TOOL 6926–2 INSTALLER (4) Install flex plate. Apply Mopart Lock & Seal Adhesive to bolt threads and tighten bolts to 95 N·m (70 ft. lbs.). (5) Install transaxle. Refer to TRANSMISSION/ TRANSAXLE - INSTALLATION for procedure. PISTON & CONNECTING ROD DESCRIPTION The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged powdered metal connecting rods. The pistons pin is offset 1 mm (0.0394 in.) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. Hex head cap screws are used to provide alignment and durability in the assembly. The pistons and connecting rods are serviced as an assembly. OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft. (1) 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. (2) Pistons have a directional stamping in the front half of the piston facing towards the front of engine (Fig. 65). (3) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (4) Remove Balance Shaft Carrier Assembly (Refer to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT CARRIER - REMOVAL). (5) Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap (Fig. 66). CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur. (6) Remove connecting rod bolts and cap. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts. (7) Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. (8) Push piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 9 - 46 ENGINE 2.4L RS PISTON & CONNECTING ROD (Continued) (9) After removal, install bearing cap on the mating rod. (10) Repeat procedure for each piston and connecting rod assembly. (11) Piston and connecting rods are serviced as an assembly. Fig. 68 Piston—Installation Fig. 66 Identify Connecting Rod to Cylinder INSTALLATION (1) Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 67). (2) Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 67). As viewed from top. (4) The directional stamp on the piston should face toward the front of the engine (Fig. 65). (5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. (6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. NOTE: The connecting rod cap bolts should not be reused. (7) Before installing the NEW bolts the threads should be coated with clean engine oil. (8) Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. CAUTION: Do not use a torque wrench for second part of last step. Fig. 67 Piston Ring End Gap Position 1 2 3 4 - GAP OF LOWER SIDE RAIL NO. 1 RING GAP GAP OF UPPER SIDE RAIL NO. 2 RING GAP AND SPACER EXPANDER GAP (3) Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Fig. 68). Be sure position of rings does not change during this operation . (9) Tighten the bolts to 27 N·m PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn). (10) Using a feeler gauge, check connecting rod side clearance (Fig. 69). (11) Install Balance Shaft Carrier Assembly (Refer to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT CARRIER - INSTALLATION). (12) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (13) Install cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - INSTALLATION). ENGINE 2.4L RS 9 - 47 PISTON & CONNECTING ROD (Continued) Fig. 69 Checking Connecting Rod Side Clearance PISTON RINGS Fig. 71 Piston Ring Side Clearance 1 - FEELER GAUGE STANDARD PROCEDURE PISTON RING - FITTING (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge (Fig. 70). Refer to Engine Specifications. Fig. 72 Piston Ring Installation 1 2 3 4 5 - NO. 1 PISTON RING NO. 2 PISTON RING SIDE RAIL OIL RING SPACER EXPANDER CAUTION: Install piston rings in the following order: Fig. 70 Piston Ring Gap 1 - FEELER GAUGE (2) Check piston ring to groove side clearance (Fig. 71). Refer to Engine Specifications. PISTON RINGS - INSTALLATION (1) Install rings with manufacturers I.D. mark facing up, to the top of the piston (Fig. 72). • Oil ring expander. • Upper oil ring side rail. • Lower oil ring side rail. • No. 2 Intermediate piston ring. • No. 1 Upper piston ring. (2) Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander (Fig. 73). 9 - 48 ENGINE 2.4L RS PISTON RINGS (Continued) (3) Install upper side rail first and then the lower side rail. (4) Install No. 2 piston ring and then No. 1 piston ring. VIBRATION DAMPER REMOVAL (1) Remove accesory drive belts. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL) (2) Remove crankshaft damper bolt. (3) Remove damper using Special Tool 3-Jaw Puller 1026 and Insert 6827–A (Fig. 75). Fig. 73 Installing Side Rail 1 - SIDE RAIL END (5) Position piston ring end gaps as shown in (Fig. 74). (6) Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control. Fig. 75 Crankshaft Vibration Damper - Removal 1 - SPECIAL TOOL 1026 3-JAW PULLER 2 - SPECIAL TOOL 6827–A INSERT INSTALLATION (1) Install crankshaft vibration damper using M12 1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792 (Fig. 76). (2) Install crankshaft vibration damper bolt and tighten to 142 N·m (105 ft. lbs.). (3) Install accessory drive belts. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION) Fig. 74 Piston 1 2 3 4 - GAP OF LOWER SIDE RAIL NO. 1 RING GAP GAP OF UPPER SIDE RAIL NO. 2 RING GAP AND SPACER EXPANDER GAP Fig. 76 Crankshaft Vibration Damper - Installation 1 - M12–1.75 × 150 MM BOLT, WASHER AND THRUST BEARING FROM SPECIAL TOOL 6792 ENGINE 2.4L RS STRUCTURAL COLLAR REMOVAL (1) Raise vehicle on hoist. (2) Remove engine front mount bracket and front insulator mount. (Refer to 9 - ENGINE/ENGINE MOUNTING/FRONT MOUNT - REMOVAL) (3) Remove structural collar attaching bolts (Fig. 77). (4) Remove collar. INSTALLATION CAUTION: Torque procedure for the structural collar must be followed or damage could occur to oil pan and collar. 9 - 49 • Step 4: Final torque collar to oil pan bolts to 54 N·m (40 ft. lbs.). (2) Install engine front mount bracket and insulator. (Refer to 9 - ENGINE/ENGINE MOUNTING/ FRONT MOUNT - INSTALLATION) (3) Lower vehicle. ENGINE MOUNTING DESCRIPTION The engine mounting system consist of four mounts; right and a left side support the powertrain, and a front and a rear mount control powertrain torque. The right side mount is a hydro-type (Fig. 78), all others are of molded rubber material. (1) Perform the following steps for installing structural collar. Refer to (Fig. 77): Fig. 78 Engine Hydro-type Mount - Right Side Fig. 77 Structural Collar 1 2 3 4 - BOLT - COLLAR TO OIL PAN BOLT - COLLAR TO TRANSAXLE STRUCTURAL COLLAR OIL PAN • Step 1: Position collar between transaxle and oil pan. Install collar to transaxle bolt, hand start only. • Step 2: Install collar to oil pan bolts, hand snug only. • Step 3: Final torque collar to transaxle bolts to 101 N·m (75 ft. lbs.) 1 2 3 4 5 - BOLT BOLT FRAME RAIL RIGHT MOUNT - 2.4L ENGINE RIGHT MOUNT - 3.3/3.8L ENGINE FRONT MOUNT REMOVAL (1) Raise vehicle on hoist. (2) Remove the front engine mount through bolt from the insulator (Fig. 79). (3) Remove the engine front mount bolts and remove the insulator assembly (Fig. 79). (4) Remove the front mounting bracket from engine, if necessary (Fig. 79). 9 - 50 ENGINE 2.4L RS FRONT MOUNT (Continued) Fig. 80 LEFT MOUNT TO BRACKET Fig. 79 Front Mount and Bracket 1 2 3 4 5 6 7 - BRACKET - FRONT MOUNT NUT - 68 N·m (50 ft. lbs.) BOLT - 54 N·m (40 ft. lbs.) MOUNT - FRONT INSULATOR BOLT - 68 N·m (50 ft. lbs.) BOLT - 68 N·m (50 ft. lbs.) FRONT CROSSMEMBER 1 2 3 4 5 6 - BOLT - BRACKET TO FRAME RAIL 68 N·m (50 ft. lbs.) BOLT - MOUNT TO RAIL THRU 75 N·m (55 ft. lbs.) BOLT - LEFT MOUNT TO TRANSAXLE 54 N·m (40 ft. lbs.) TRANSAXLE MOUNT - LEFT BRACKET - LEFT MOUNT NOTE: To remove mount, additional lowering of transaxle may be required. (9) Remove left mount. INSTALLATION (1) Install the front mount bracket to engine, if removed (Fig. 79). (2) Install the insulator mount assembly (Fig. 79). (3) Install the front engine mount through bolt to the insulator (Fig. 79). (4) Lower the vehicle. LEFT MOUNT REMOVAL (1) Raise the vehicle on hoist. (2) Remove the left front wheel. (3) Remove the left mount through bolt access cover. (4) Support the transaxle with a suitable jack. (5) Remove the engine front mount through bolt to allow left mount removal clearance (Fig. 79). (6) Remove the left mount through frame rail bolt (Fig. 80). (7) Lower transaxle for access to horizontal bolts. (8) Remove the horizontal bolts from the mount to the transaxle (Fig. 81) or (Fig. 82). Fig. 81 LEFT MOUNT - 31TH 1 - LEFT MOUNT ASEMBLY 2 - BOLT - 54 N·m (40 ft. lbs.) 3 - TRANSAXLE - 31TH INSTALLATION (1) Install left mount on transaxle (Fig. 81) or (Fig. 82). ENGINE 2.4L RS LEFT MOUNT (Continued) Fig. 83 REAR MOUNT HEAT SHIELD Fig. 82 UNDER CONSTRUCTION 1 - LEFT MOUNT ASSEMBLY 2 - BOLT - 54 N·m (40 ft. lbs.) 3 - TRANSAXLE - 41TE 1 2 3 4 - BOLT - HEAT SHIELD 11 N·m (100 in. lbs.) HEAT SHIELD CLIP REAR MOUNT (2) Raise transaxle with jack until left mount is in position. (3) Install left mount through bolt (Fig. 80). (4) Install left mount through bolt access cover. (5) Install front mount through bolt (Fig. 79). (6) Install left front wheel. (7) Lower vehicle. REAR MOUNT REMOVAL (1) Raise vehicle on hoist. (2) Remove the rear mount heat shield (Fig. 83). (3) Remove the through bolt from the mount and rear mount bracket (Fig. 84). (4) Remove the mount bolts (Fig. 84). (5) Remove the rear mount (Fig. 84). (6) For rear mount bracket removal, remove the bolts attaching bracket to transaxle (Fig. 85). (7) Remove rear mount bracket. INSTALLATION (1) Install rear mount bracket, if removed (Fig. 85). (2) Install the rear mount and bolts (Fig. 84). Tighten bolts to 54 N·m (40 ft. lbs.). (3) Install the mount through bolt to the mount and bracket (Fig. 84). Tighten through bolt to 54 N·m (40 ft. lbs.). (4) Install the rear mount heat shield (Fig. 83). (5) Lower vehicle on hoist. Fig. 84 REAR MOUNT 1 2 3 4 - BOLT 54 N·m (40 ft. lbs.) REAR MOUNT BRACKET THRU-BOLT 54 N·m (40 ft. lbs.) REAR MOUNT 9 - 51 9 - 52 ENGINE 2.4L RS REAR MOUNT (Continued) Fig. 85 REAR MOUNT BRACKET - (all engines) 1 - BOLT - VERTICAL 102 N·m (75 ft. lbs.) 2 - BRACKET - REAR MOUNT RIGHT MOUNT REMOVAL (1) Remove air cleaner housing lid and clean air hose from throttle body. (2) Remove air cleaner element and housing. (3) Disconnect make-up air hose from cylinder head cover. (4) Remove the load on the right engine mount by carefully supporting the engine assembly with a floor jack. (5) Disconnect electrical harness support clips from engine mount bracket. (6) Remove the vertical bolts attaching the engine mount to the frame rail (Fig. 86). (7) Loosen the horizontal bolt attaching the engine mount to the frame rail (Fig. 86). (8) Remove the bolts attaching the engine mount to the engine bracket (Fig. 86). (9) Remove the right engine mount (Fig. 86). 3 - BOLT - HORIZONTAL 102 N·m (75 ft. lbs.) INSTALLATION (1) Position right engine mount and install frame rail to mount vertical bolts (Fig. 86). (2) Tighten engine right mount to rail horizontal bolt (Fig. 86). (3) Install mount to engine bracket bolts (Fig. 86). (4) Connect electrical harness support clips to engine mount bracket. (5) Remove jack from under engine. (6) Connect make-up air hose to cylinder head cover. (7) Install air cleaner housing and element. (8) Install air cleaner housing lid and clean air tube to throttle body. ENGINE 2.4L RS 9 - 53 RIGHT MOUNT (Continued) running the length of the cylinder head. The camshaft journals are partially slotted to allow a predetermined amount of pressurized oil to pass into the bearing cap cavities. Lubrication of the camshaft lobes are provided by small holes in the camshaft bearing caps that are directed towards each lobe. Oil returning to the pan from pressurized components supplies lubrication to the valve stems. Cylinder bores and wrist pins are splash lubricated from directed slots on the connecting rod thrust collars. DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE (1) Disconnect and remove oil pressure switch. (Refer to 9 - ENGINE/LUBRICATION/OIL PRESSURE SENSOR/SWITCH - REMOVAL) (2) Install Special Tools C-3292 Gauge with 8406 Adaptor fitting. (3) Start engine and record oil pressure. Refer to Specifications for correct oil pressure requirements. (Refer to 9 - ENGINE - SPECIFICATIONS) CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test Fig. 86 RIGHT MOUNT TO RAIL AND ENGINE 1 2 3 4 5 - BOLT - MOUNT TO RAIL 68 N·m (50 ft. lbs.) BOLT - MOUNT TO ENGINE 54 N·m (40 ft. lbs.) BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N·m (50 ft. lbs.) RIGHT ENGINE MOUNT RIGHT FRAME RAIL LUBRICATION (4) If oil pressure is 0 at idle. Shut off engine, check for pressure relief valve stuck open, a clogged oil pick-up screen or a damaged oil pick-up tube O-ring. (5) After test is complete, remove test gauge and fitting. (6) Install oil pressure switch and connector. (Refer to 9 - ENGINE/LUBRICATION/OIL PRESSURE SENSOR/SWITCH - INSTALLATION) DESCRIPTION The lubrication system is a full-flow filtration, pressure feed type. The oil pump is mounted in the front engine cover and driven by the crankshaft. OPERATION Engine oil drawn up through the pickup tube and is pressurized by the oil pump and routed through the full-flow filter to the main oil gallery running the length of the cylinder block. A diagonal hole in each bulkhead feeds oil to each main bearing. Drilled passages within the crankshaft route oil from main bearing journals to connecting rod journals. Balance shaft lubrication is provided through an oil passage from the number one main bearing cap through the balance shaft carrier support leg. This passage directly supplies oil to the front bearings and internal machined passages in the shafts that routes oil from front to the rear shaft bearing journals. A vertical hole at the number five bulkhead routes pressurized oil through a restrictor (integral to the cylinder head gasket) up past a cylinder head bolt to an oil gallery OIL STANDARD PROCEDURE ENGINE OIL LEVEL CHECK The best time to check engine oil level is after it has sat overnight, or if the engine has been running, 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 and observe oil level. Add oil only when the level is at or below the ADD mark (Fig. 87). 9 - 54 ENGINE 2.4L RS OIL (Continued) (12) Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Fig. 87 Oil Level 1 - ENGINE OIL LEVEL DIPSTICK OIL FILTER DESCRIPTION STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. (Refer to LUBRICATION & MAINTENANCE/MAINTENANCE SCHEDULES - DESCRIPTION) 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. Run engine until achieving normal operating temperature. (1) Position the vehicle on a level surface and turn engine off. (2) Remove oil fill cap. (3) Hoist and support vehicle on safety stands. Refer to Hoisting and Jacking Recommendations. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Place a suitable drain pan under crankcase drain. (5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. (6) Remove oil filter. (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - REMOVAL) (7) Install and tighten drain plug in crankcase. (8) Install new oil filter. (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION) (9) Lower vehicle and fill crankcase with specified type and amount of engine oil. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES DESCRIPTION) (10) Install oil fill cap. (11) Start engine and inspect for leaks. The engine oil filter (Fig. 88) is a high quality fullflow, disposable type. Replace the oil filter with a Mopart or the equivalent. REMOVAL (1) Raise vehicle on hoist. (2) Position an oil collecting container under oil filter location. 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. (3) Using a suitable filter wrench, turn oil filter (Fig. 88) counterclockwise to remove. Fig. 88 Oil Filter ENGINE 2.4L RS 9 - 55 OIL FILTER (Continued) 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 with clean engine oil. (3) Screw oil filter (Fig. 88) on until the gasket contacts base. Tighten to 12 N·m (105 in. lbs.). OIL PRESSURE SWITCH REMOVAL (1) Raise vehicle. (2) Position oil collecting container under pressure switch location. (3) Disconnect oil pressure switch electrical connector and remove switch (Fig. 90). OIL PAN REMOVAL (1) Raise vehicle on hoist and drain engine oil. (2) Remove structural collar. (Refer to 9 ENGINE/ENGINE BLOCK/STRUCTURAL COVER REMOVAL) (3) Remove air conditioning compressor bracket to oil pan bolt. (4) Remove bolts attaching oil pan. (5) Remove oil pan. (6) Clean oil pan and all gasket surfaces. INSTALLATION (1) Apply Mopart Engine RTV GEN II at the oil pump to engine block parting line (Fig. 89). Fig. 90 Engine Oil Pressure Switch INSTALLATION (1) Install oil pressure switch. Torque switch to 21 N·m (190 in. lbs.) (Fig. 90). (2) Connect electrical connector (3) Lower vehicle. (4) Start engine and allow to run a minimum of 2 minutes. (5) Shut engine off and check engine oil level. Adjust level as necessary. OIL PUMP REMOVAL Fig. 89 Oil Pan Sealing - Typical 1 - SEALER LOCATIONS (2) Install the oil pan gasket to the block. (3) Install pan and tighten the screws to 12 N·m (105 in. lbs.). (4) Install air conditioning compressor bracket to oil pan bolt. (5) Install structural collar. (Refer to 9 - ENGINE/ ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION) (6) Lower vehicle and fill engine crankcase with proper oil to correct level. (1) Disconnect negative cable from battery. (2) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS REMOVAL). (3) Remove timing belt rear cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL). (4) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (5) Remove crankshaft sprocket using Special Tools 6793 and C-4685-C2 (Fig. 91). (6) Remove crankshaft key (Fig. 92). (7) Remove oil pick-up tube. (8) Remove oil pump (Fig. 93) and front crankshaft seal. 9 - 56 ENGINE 2.4L RS OIL PUMP (Continued) Fig. 91 Crankshaft Sprocket - Removal 1 - SPECIAL TOOL 6793 2 - SPECIAL TOOL C-4685–C2 3 - CRANKSHAFT SPROCKET Fig. 93 Oil Pump 1 - BOLTS 2 - BOLTS 3 - OIL PUMP Fig. 92 Crankshaft Key 1 - CRANKSHAFT KEY DISASSEMBLY (1) To remove the relief valve, proceed as follows: (a) Remove the threaded plug and gasket from the oil pump (Fig. 94) . (b) Remove spring and relief valve (Fig. 94) . (2) Remove oil pump cover fasteners, and lift off cover (Fig. 95) . (3) Remove pump rotors (Fig. 95) . (4) Wash all parts in a suitable solvent and inspect carefully for damage or wear. Fig. 94 Oil Pressure Relief Valve 1 2 3 4 5 - PLUG OIL PUMP BODY RELIEF VALVE SPRING SEAL ENGINE 2.4L RS 9 - 57 OIL PUMP (Continued) Fig. 95 Oil Pump 1 2 3 4 5 6 7 - O-RING SEAL INNER ROTOR OIL PUMP COVER FASTENER OUTER ROTOR OIL PUMP BODY Fig. 96 Oil Pump 1 2 3 4 5 6 7 - O-RING SEAL INNER ROTOR OIL PUMP COVER FASTENER OUTER ROTOR OIL PUMP BODY CLEANING (1) Clean all parts thoroughly in a suitable solvent. INSPECTION (1) Inspect the mating surface of the oil pump. Surface should be smooth (Fig. 96) . Replace pump cover if scratched or grooved. (2) Lay a straightedge across the pump cover surface (Fig. 97) . If a 0.025 mm (0.001 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced. (3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 9.40 mm (0.370 in.) or less (Fig. 98) , or if the diameter is 79.95 mm (3.148 in.) or less, replace outer rotor. (4) If inner rotor measures 9.40 mm (0.370 in.) or less replace inner rotor (Fig. 99) . Fig. 97 Checking Oil Pump Cover Flatness 1 - STRAIGHT EDGE 2 - FEELER GAUGE 3 - OIL PUMP COVER 9 - 58 ENGINE 2.4L RS OIL PUMP (Continued) (2) Apply Mopart Gasket Maker to oil pump as shown in (Fig. 100). Install O-ring into oil pump body discharge passage. Fig. 98 Measuring Outer Rotor Thickness Fig. 100 Oil Pump Sealing 1 - O-RING 2 - SEALER LOCATION (3) Prime oil pump with engine oil before installation. (4) Align oil pump rotor flats with flats on crankshaft. Install the oil pump to the block (Fig. 93). CAUTION: To align, the front crankshaft seal MUST be out of pump, or damage may result. Fig. 99 Measuring Inner Rotor Thickness ASSEMBLY (1) Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover. (2) Prime oil pump before installation by filling rotor cavity with engine oil. (3) Install cover and tighten fasteners to 12 N·m (105 in. lbs.) (Fig. 95). CAUTION: Oil pump pressure relief valve must be installed as shown in (Fig. 94) or serious engine damage may occur. (4) Install relief valve, spring, gasket and cap as shown in (Fig. 94). Tighten cap to 41 N·m (30 ft. lbs.). INSTALLATION (1) Make sure all surfaces are clean and free of oil and dirt. (5) Install new front crankshaft seal using Special Tool 6780 (Fig. 101). (6) Install crankshaft key (Fig. 92). CAUTION: The crankshaft sprocket is set to a predetermined depth from the factory for correct timing belt tracking. If removed, use of Special Tool 6792 is required to set the sprocket to original installation depth. An incorrectly installed sprocket will result in timing belt and engine damage. (7) Install crankshaft sprocket using Special Tool 6792 (Fig. 102). (8) Install oil pump pick-up tube. (9) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (10) Install timing belt rear cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION). (11) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS INSTALLATION). ENGINE 2.4L RS 9 - 59 OIL PUMP (Continued) INTAKE MANIFOLD DESCRIPTION The intake manifold is a two piece aluminum casting (Fig. 103) that attaches to the cylinder head with fasteners. The manifold is a long branch design to enhance low and mid-range torque Fig. 101 Front Crankshaft Seal - Installation 1 - PROTECTOR 2 - SEAL 3 - SPECIAL TOOL 6780 Fig. 103 Intake Manifold - Upper and Lower 1 - UPPER INTAKE MANIFOLD 2 - LOWER INTAKE MANIFOLD OPERATION The intake manifold delivers air to the combustion chambers. This air allows the fuel delivered by the fuel injectors to ignite when the spark plugs fire. DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. 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. Fig. 102 Crankshaft Sprocket - Installation 1 - SPECIAL TOOL 6792 2 - TIGHTEN NUT TO INSTALL (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. 9 - 60 ENGINE 2.4L RS INTAKE MANIFOLD - UPPER REMOVAL (1) Disconnect negative cable from battery. (2) Disconnect connector from inlet air temperature sensor (Fig. 104). Fig. 106 Throttle Body Electrical Connectors Typical 1 - IDLE AIR CONTROL MOTOR CONNECTOR 2 - TPS CONNECTOR Fig. 104 INLET AIR TEMPERATURE SENSOR - 2.4L (3) Disconnect air intake tube at throttle body and remove upper air cleaner housing. (4) Disconnect connector from throttle position sensor (TPS) (Fig. 106). (5) Disconnect connector from idle air control (IAC) motor (Fig. 106). (6) Disconnect connector from MAP sensor (Fig. 105). (8) Remove vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at upper intake manifold fittings. (9) Disconnect throttle, speed control (if equipped), and transaxle control (31TH equipped only) cables from throttle lever and bracket. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE CONTROL CABLE - REMOVAL) (10) Remove the EGR tube. (Refer to 25 - EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/TUBE - REMOVAL) (11) Remove the upper manifold support bracket bolt to manifold (Fig. 107). Fig. 107 Upper Intake Manifold Support Bracket Fig. 105 MAP SENSOR - 2.4L (7) Remove vacuum lines for purge solenoid and PCV valve at intake manifold. 1 - NUT - BRACKET TO CYLINDER HEAD COVER 2 - BOLT - BRACKET TO UPPER INTAKE MANIFOLD 3 - UPPER INTAKE MANIFOLD SUPPORT BRACKET ENGINE 2.4L RS 9 - 61 INTAKE MANIFOLD - UPPER (Continued) (12) Remove engine oil dipstick from tube. (13) Remove upper intake manifold bolts (Fig. 108). Remove upper intake manifold. CAUTION: Cover intake manifold to prevent foreign material from entering engine. INSPECTION (1) Check manifold 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 manifold for cracks or distortion. Replace manifold if necessary. INSTALLATION (1) Clean manifold sealing surfaces. (2) Apply a 1.5 mm (0.060 in.) bead Mopart Gasket Maker to the perimeter of the lower intake manifold runner openings. (3) Install upper intake manifold and tighten fasteners to 28 N·m (250 in. lbs.) in sequence shown in (Fig. 108). Repeat this procedures until all fasteners are at specified torque. Fig. 108 Upper Intake Manifold Tightening Sequence - 2.4L (4) Install engine oil dipstick. (5) Install upper bolt in intake manifold to front support bracket (Fig. 107). Torque to 28 N·m (250 in. lbs.). (6) Install EGR tube. (Refer to 25 - EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/ TUBE - INSTALLATION) (7) Install throttle cables in bracket. (8) Connect throttle, speed control, (if equipped), transaxle control (31TH equipped only) cables to throttle lever. (9) Connect vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at upper intake manifold fittings. (10) Connect vacuum lines for purge solenoid and PCV valve. (11) Connect electrical connectors for MAP sensor, throttle position sensor (TPS), and idle air control (IAC) motor. (12) Install air cleaner upper housing and air intake tube to throttle body. (13) Connect inlet air temperature sensor connector (Fig. 104). (14) Connect negative cable to battery. INTAKE MANIFOLD - LOWER REMOVAL (1) Perform fuel system pressure release procedure before attempting any repairs. (Refer to 14 FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE) (2) Remove upper intake manifold. (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL) CAUTION: Cover intake manifold openings to prevent foreign material from entering engine. (3) Disconnect fuel line. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) (4) Drain the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (5) Remove heater supply and radiator upper hoses at intake manifold. (6) Disconnect coolant temperature sensor/fuel injector wire harness connector. (7) Remove lower intake manifold support bracket upper bolts (Fig. 109). (8) Loosen the lower intake manfold support bracket lower bolt (Fig. 109). (9) Disconnect fuel injector harness. (10) Remove the bolts attaching the power steering reservoir to manifold. Set reservoir aside. Do not disconnect line from reservoir. (11) Remove lower intake manifold fasteners (Fig. 110). Remove the manifold from engine. (12) Inspect the manifold. (Refer to 9 - ENGINE/ MANIFOLDS/INTAKE MANIFOLD - INSPECTION) INSPECTION (1) Check manifold 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 manifold for cracks or distortion. Replace manifold if necessary. INSTALLATION If the following items were removed, install and torque to specifications: • Fuel rail bolts - 22 N·m (200 in. lbs.) 9 - 62 ENGINE 2.4L RS INTAKE MANIFOLD - LOWER (Continued) (5) Connect the fuel line. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) (6) Connect coolant temperature sensor/fuel injector wiring harness electrical connector. (7) Install the radiator upper and heater supply hoses. (8) Install the upper intake manifold. (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD INSTALLATION) (9) Fill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) EXHAUST MANIFOLD DESCRIPTION Fig. 109 Lower Intake Manifold Support Bracket 1 - SUPPORT BRACKET 2 - BOLTS - UPPER TO MANIFOLD 3 - BOLT - LOWER TO ENGINE BLOCK • Coolant outlet connector bolts - 28 N·m (250 in. lbs.) • Coolant temperature sensor - 7 N·m (60 in. lbs.) (1) Position a new gasket on cylinder head and install lower manifold. (2) Install and tighten intake manifold fasteners to 28 N·m (250 in. lbs.) in the sequence shown in (Fig. 110). Repeat procedure until all bolts are at specified torque. The exhaust manifold is made of Hi-Silicone Moly nodular cast iron for strength and high temperatures. The manifold attaches to the cylinder head. OPERATION The exhaust manifold collects the exhaust gasses exiting the combustion chambers. Then it channels the exhaust gasses to the exhaust pipe attached to the manifold. REMOVAL (1) Raise vehicle and disconnect exhaust pipe from the exhaust manifold. (2) Disconnect upstream oxygen sensor connector at the rear of exhaust manifold. (3) Remove the bolts attaching the manifold to the cylinder head. (4) Remove exhaust manifold. (5) Inspect the manifold. (Refer to 9 - ENGINE/ MANIFOLDS/EXHAUST MANIFOLD - INSPECTION) CLEANING (1) Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head. INSPECTION Fig. 110 Lower Intake Manifold Tightening Sequence (3) Install lower intake manifold support bracket bolts (Fig. 109) and tighten to: • Bolts to intake 28 N·m (250 in. lbs.) • Bolt to engine block 54 N·m (40 ft. lbs.) (4) Position power steering reservoir on manifold and install bolts. (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. INSTALLATION (1) Install exhaust manifold with a new gasket. Tighten attaching nuts in the sequence shown in (Fig. 111) to 19 N·m (170 in. lbs.). ENGINE 2.4L RS 9 - 63 EXHAUST MANIFOLD (Continued) (2) Attach exhaust pipe to exhaust manifold and tighten fasteners to 37 N·m (27 ft. lbs.). (3) Install and connect the oxygen sensor. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR - COMPONENT LOCATION) Fig. 111 Exhaust Manifold Tightening Sequence TIMING BELT COVER(S) REMOVAL FRONT COVER (1) Remove crankshaft vibration damper. (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) (2) Remove generator drive belt tensioner assembly. (Refer to 7 - COOLING/ACCESSORY DRIVE/ BELT TENSIONERS - REMOVAL) (3) Remove timing belt front cover bolts (Fig. 112) and remove covers. REAR COVER (1) Remove front covers. (2) Remove engine mount bracket (Fig. 113). (3) Remove timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (4) Hold camshaft sprocket with Special Tool 6847 while removing center bolt (Fig. 114). (5) Remove timing belt idler pulley. (6) Remove rear cover fasteners and remove cover from engine (Fig. 115). INSTALLATION REAR COVER (1) Install timing belt rear cover and bolts (Fig. 115). Fig. 112 Timing Belt Front Covers 1 - BOLTS - UPPER FRONT COVER 7 N·m (60 in. lbs.) 2 - BOLTS - LOWER FRONT COVER 7 N·m (60 in. lbs.) CAUTION: Do not use an impact wrench for tightening camshaft sprocket bolt. Damage to the timing locating pin can occur. Hand tighten using a wrench ONLY. (2) Install camshaft sprockets. Hold sprockets with Special Tool 6848 and tighten center bolt to 101 N·m (75 ft. lbs.). (3) Install timing belt idler pulley and tighten mounting bolt to 61 N·m (45 ft. lbs.). (4) Install timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) (5) Install engine mount bracket and tighten bolts to 61 N·m (45 ft. lbs.) (Fig. 113). (6) Install front covers. FRONT COVER (1) Install timing belt front covers (Fig. 112). Tighten fasteners to 7 N·m (60 in. lbs.). (2) Install generator drive belt tensioner. (Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION) 9 - 64 ENGINE 2.4L RS TIMING BELT COVER(S) (Continued) Fig. 113 ENGINE FRONT MOUNT BRACKET 1 - ENGINE MOUNT BRACKET 2 - BOLTS - 61 N·m (45 ft. lbs.) Fig. 115 Timing Belt Rear Cover 1 - BOLTS - REAR COVER 12 N·m (105 in. lbs.) 2 - BOLTS - REAR COVER 28 N·m (250 in. lbs.) 3 - TIMING BELT TENSIONER (3) Install crankshaft vibration damper. (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER INSTALLATION) TIMING BELT AND SPROCKET(S) REMOVAL REMOVAL - TIMING BELT Fig. 114 Camshaft Sprocket - Removal/Installation 1 - SPECIAL TOOL 6847 (1) Remove air cleaner upper cover, housing, and clean air tube. (2) Remove make-up air hose from cylinder head cover. (3) Raise vehicle on hoist. (4) Remove right front wheel. (5) Remove right inner splash shield. (6) Remove accessory drive belts. (Refer to 7 COOLING/ACCESSORY DRIVE/BELT TENSIONERS - REMOVAL) ENGINE 2.4L RS 9 - 65 TIMING BELT AND SPROCKET(S) (Continued) (7) Remove crankshaft vibration damper. (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) (8) Remove air conditioner/generator belt tensioner and pulley assembly. (Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSIONERS - REMOVAL) (9) Remove timing belt lower front cover bolts and remove cover. (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT / CHAIN COVER(S) - REMOVAL) (10) Lower vehicle. (11) Remove bolts attaching timing belt upper front cover and remove cover. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (12) Remove right engine mount. (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT REMOVAL) (13) Remove engine mount bracket (Fig. 116). CAUTION: When aligning crankshaft and camshaft timing marks always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt. (14) Before the removal of the timing belt, rotate crankshaft until the TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth) (Fig. 117). NOTE: The crankshaft sprocket TDC mark is located on the trailing edge of the sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause the camshaft timing marks to be misaligned. Fig. 117 Crankshaft and Camshaft Timing 1 - CAMSHAFT TIMING MARKS 2 - CRANKSHAFT TDC MARKS 3 - TRAILING EDGE OF SPROCKET TOOTH Fig. 116 Engine Mount Bracket 1 - ENGINE MOUNT BRACKET 2 - BOLTS - 61 N·m (45 ft. lbs.) (15) Install 6 mm Allen wrench into belt tensioner. Before rotating the tensioner, insert the long end of a 1/8” or 3 mm Allen wrench into the pin hole on the front of the tensioner (Fig. 118). While rotating the tensioner counterclockwise, push in lightly on the 1/8” or 3 mm Allen wrench, until it slides into the locking hole. (16) Remove timing belt. 9 - 66 ENGINE 2.4L RS TIMING BELT AND SPROCKET(S) (Continued) CLEANING Do Not attempt to clean a timing belt. If contamination from oil, grease, or coolants have occurred, the timing belt should be replaced. Clean all sprockets using a suitable solvent. Clean all sprocket grooves of any debris. INSTALLATION INSTALLATION - CRANKSHAFT SPROCKET CAUTION: The crankshaft sprocket is set to a predetermined depth from the factory for correct timing belt tracking. If removed, use of Special Tool 6792 is required to set the sprocket to original installation depth. An incorrectly installed sprocket will result in timing belt and engine damage. (1) Install crankshaft sprocket using Special Tool 6792 (Fig. 120). Fig. 118 Locking Timing Tensioner 1 - 1/8 OR 3mm ALLEN WRENCH 2 - BELT TENSIONER 3 - 6mm ALLEN WRENCH REMOVAL - CRANKSHAFT SPROCKET (1) Disconnect negative battery cable. (2) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (3) Remove crankshaft sprocket using Special Tools 6793 and insert C-4685-C2 (Fig. 119). Fig. 120 Crankshaft Sprocket - Installation 1 - SPECIAL TOOL 6792 2 - TIGHTEN NUT TO INSTALL (2) Install timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) Fig. 119 Crankshaft Sprocket - Removal 1 - SPECIAL TOOL 6793 2 - SPECIAL TOOL C-4685–C2 3 - CRANKSHAFT SPROCKET ENGINE 2.4L RS 9 - 67 TIMING BELT AND SPROCKET(S) (Continued) INSTALLATION - TIMING BELT NOTE: A new tensioner is held in the wound position by a pull pin. CAUTION: The crankshaft sprocket is set to a predetermined depth from the factory for correct timing belt tracking. If removed, use of Special Tool 6792 is required to set the sprocket to original installation depth. An incorrectly installed sprocket will result in timing belt and engine damage. (1) Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. (2) Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket (Fig. 121). CAUTION: Ensure that the arrows on both camshaft sprockets are facing up. Fig. 121 Camshaft Sprocket Alignment 1 - CAMSHAFT SPROCKET-EXHAUST 2 - CAMSHAFT SPROCKET-INTAKE 3 - 1/2 NOTCH LOCATION (3) Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner (Fig. 122). (4) Move the exhaust camshaft sprocket counterclockwise (Fig. 122) to align marks and take up belt slack. Fig. 122 Timing Belt - Installation 1 2 3 4 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION CRANKSHAFT AT TDC INSTALL BELT IN THIS DIRECTION 9 - 68 ENGINE 2.4L RS TIMING BELT AND SPROCKET(S) (Continued) (5) Remove the pull pin or Allen wrench from the belt tensioner. (6) Once the timing belt has been installed and tensioner released, rotate the crankshaft two (2) complete revolutions. Verify that the TDC marks on crankshaft and timing marks on the camshafts are aligned as shown in (Fig. 123). (11) Install crankshaft vibration damper. (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) (12) Install accessory drive belts. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION) (13) Install drive belt splash shield. (14) Install right front wheel. (15) Connect make-up air hose to cylinder head cover. (16) Install air cleaner housing, upper cover, and clean air tube. TIMING BELT TENSIONER & PULLEY REMOVAL (1) Remove the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS REMOVAL). (2) Remove timing belt idler pulley. (3) Hold camshaft sprocket with Special Tool 6847 while removing bolt (Fig. 124). Remove both cam sprockets. Fig. 123 Crankshaft and Camshaft Timing 1 - CAMSHAFT TIMING MARKS 2 - CRANKSHAFT TDC MARKS 3 - TRAILING EDGE OF SPROCKET TOOTH (7) Install engine mount bracket to engine (Fig. 116). (8) Install timing belt front covers and bolts. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (9) Install air conditioning/generator belt tensioner and pulley. (Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION) (10) Install right engine mount. (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION) Fig. 124 Camshaft Sprocket - Removal/Installation 1 - SPECIAL TOOL 6847 ENGINE 2.4L RS 9 - 69 TIMING BELT TENSIONER & PULLEY (Continued) Fig. 126 Timing Belt Tensioner Assembly—Removal/ Installation 1 - TIMING BELT TENSIONER ASSEMBLY 2 - TENSIONER ASSEMBLY UPPER BOLT 3 - TENSIONER ASSEMBLY LOWER BOLT Fig. 125 Rear Timing Belt Cover Fasteners 1 - BOLTS - REAR COVER 12 N·m (105 in. lbs.) 2 - BOLTS - REAR COVER 28 N·m (250 in. lbs.) 3 - TIMING BELT TENSIONER (4) Remove rear timing belt cover fasteners and remove cover from engine (Fig. 125). (5) Remove lower bolt attaching timing belt tensioner assembly to engine and remove tensioner as an assembly (Fig. 126). INSTALLATION (1) Align timing belt tensioner assembly to engine and install lower mounting bolt but do not tighten (Fig. 126). To properly align tensioner assembly—install one of the engine bracket mounting bolts (M10) 5 to 7 turns into the tensioner’s upper mounting location (Fig. 126). (2) Torque the tensioner’s lower mounting bolt to 61 N·m (45 ft. lbs.). Remove the upper bolt used for tensioner alignment. (3) Install rear timing belt cover and fasteners (Fig. 125). (4) Install timing belt idler pulley and torque mounting bolt to 61 N·m (45 ft. lbs.). (5) Install camshaft sprockets. Use Special Tool 6847 to hold sprockets (Fig. 124), torque bolts to 101 N·m (75 ft. lbs.). (6) Install the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS INSTALLATION). BALANCE SHAFTS AND CARRIER ASSEMBLY DESCRIPTION The 2.4L engine is equipped with two nodular cast iron balance shafts installed in a cast aluminum carrier attached to the lower cylinder block (Fig. 127). 9 - 70 ENGINE 2.4L RS BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 127 Balance Shafts and Carrier Assembly 1 2 3 4 5 6 - SPROCKET TENSIONER PLUG CARRIER REAR COVER BALANCE SHAFTS OPERATION The balance shafts are driven by the crankshaft via a roller chain and sprockets. The balance shafts are connected by helical gears. The dual counter rotating shafts decrease second order vertical shaking forces caused by component movement. REMOVAL BALANCE SHAFTS/CHAIN/SPROCKETS NOTE: For service procedures requiring only temporary relocation of carrier assembly refer to BALANCE SHAFT CARRIER procedure below. (1) Drain engine oil. (2) Remove the oil pan and pick-up tube (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (3) If replacing crankshaft sprocket, remove oil pump (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - REMOVAL). (4) Remove chain cover, guide and tensioner (Fig. 128). 7 - GEARS 8 - GEAR COVER 9 - CHAIN COVER 10 - SPROCKET 11 - GUIDE 12 - CHAIN (5) Remove screw retaining balance shaft drive sprocket (Fig. 129). Remove chain and sprocket. (6) Using two wide pry bars, work the crankshaft sprocket back and forth until it is off the crankshaftshaft. (7) Remove gear cover retaining stud (double ended to also retain chain guide). Remove cover and balance shaft gears (Fig. 130). (8) Remove rear cover and balance shafts (Fig. 131). (9) Remove four carrier to crankcase attaching bolts to separate carrier from engine bedplate. BALANCE SHAFT CARRIER The following components will remain intact during carrier removal: Gear cover, gears, balance shafts and the rear cover (Fig. 127). (1) Drain engine oil. (2) Remove the oil pan and pick-up tube (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (3) Remove chain cover, guide and tensioner (Fig. 128). ENGINE 2.4L RS 9 - 71 BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 128 Chain Cover, Guide and Tensioner 1 2 3 4 5 6 7 - STUD - TENSIONER (ADJUSTER) - GEAR COVER - ADJUST SCREW - PIVOT SCREW - CHAIN COVER (CUTAWAY) - GUIDE Fig. 129 Drive Chain and Sprockets 1 - NICKEL PLATED LINK AND MARK 2 - GEAR/SPROCKET SCREWS 3 - NICKEL PLATED LINK AND DOT (4) Remove screw retaining balance shaft drive sprocket (Fig. 129). (5) Move balance shaft inboard through drive chain sprocket. Sprocket will hang in lower chain loop. (6) Remove carrier to crankcase attaching bolts to remove carrier. INSTALLATION BALANCE SHAFT INSTALLATION/TIMING Balance shaft and carrier assembly installation is the reverse of the removal procedure. During installation crankshaft-to-balance shaft timing must be established. Refer to Timing procedure in this section. (1) With balance shafts installed in carrier (Fig. 127) position carrier on crankcase and install four attaching bolts and tighten to 54 N·m (40 ft. lbs.). (2) Turn balance shafts until both shaft key ways are up, parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After installation gear and balance shaft keyways must be up Fig. 130 Gear Cover and Gears 1 2 3 4 5 6 - STUD (DOUBLE ENDED) DRIVE GEAR DRIVEN GEAR CARRIER DOWEL GEAR(S) GEAR COVER with gear timing marks meshed as shown in (Fig. 132). (3) Install gear cover and tighten double ended stud/washer fastener to 12 N·m (105 in. lbs.). 9 - 72 ENGINE 2.4L RS BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 131 Balance Shaft - Removal/Installation 1 - REAR COVER 2 - CARRIER 3 - BALANCE SHAFT Fig. 133 Balance Shaft Sprocket Alignment to Crankshaft 1 - ALIGN FLATS Fig. 132 Gear Timing 1 - KEY WAYS UP 2 - GEAR ALIGNMENT DOTS (4) Align flat on balance shaft drive sprocket to the flat on crankshaft (Fig. 133). (5) Install balance shaft drive sprocket on crankshaft using Special Tool 6052 (Fig. 134). (6) Turn crankshaft until number 1 cylinder is at top dead center (TDC). The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap. (Fig. 135). (7) Place chain over crankshaft sprocket so that the plated link of the chain is over the number 1 cyl- Fig. 134 Balance Shaft Drive 1 - SPROCKET 2 - SPECIAL TOOL 6052 inder timing mark on the balance shaft crankshaft sprocket (Fig. 135). (8) Place balance shaft sprocket into the timing chain (Fig. 135) and align the timing mark on the sprocket (dot) with the (lower) plated link on the chain. NOTE: The lower plated link is 8 links from the upper link. ENGINE 2.4L RS 9 - 73 BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) (9) With balance shaft keyways pointing up (12 o’clock) slide the balance shaft sprocket onto the nose of the balance shaft. The balance shaft may have to be pushed in slightly to allow for clearance. (11) CHAIN TENSIONING: (a) Install chain tensioner loosely assembled. (b) Position guide on double ended stud making sure tab on the guide fits into slot on the gear cover. Install and tighten nut/washer assembly to 12 N·m (105 in. lbs.). (c) Place a shim 1 mm (0.039 in.) thick x 70 mm (2.75 in.) long or between tensioner and chain. Push tensioner and shim up against the chain. Apply firm pressure 2.5–3 Kg (5.5–6.6 lbs.) directly behind the adjustment slot to take up all slack. Chain must have shoe radius contact as shown in (Fig. 136). (d) With the load applied, tighten top tensioner bolt first, then bottom pivot bolt. Tighten bolts to 12 N·m (105 in. lbs.). Remove shim. (e) Install carrier covers and tighten screws to 12 N·m (105 in. lbs.). (12) If removed, install oil pump (Refer to 9 ENGINE/LUBRICATION/OIL PUMP - INSTALLATION). (13) Install pick-up tube and oil pan (Refer to 9 ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (14) Fill engine crankcase with proper oil to correct level. Fig. 135 Balance Shaft Timing 1 2 3 4 5 6 - MARK ON SPROCKET - KEYWAYS UP - ALIGN MARKS - PLATED LINK - PARTING LINE (BEDPLATE TO BLOCK) - PLATED LINK NOTE: THE TIMING MARK ON THE SPROCKET, THE (LOWER) NICKEL PLATED LINK, AND THE ARROW ON THE SIDE OF THE GEAR COVER SHOULD LINE UP WHEN THE BALANCE SHAFTS ARE TIMED CORRECTLY. (10) If the sprockets are timed correctly, install the balance shaft bolts and tighten to 28 N·m (250 in. lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation. Fig. 136 Chain Tension Adjustment 1 - 1MM (0.039 IN.) SHIM 2 - TENSIONER (ADJUSTER) BOLT 3 - PIVOT BOLT 9 - 74 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L TABLE OF CONTENTS page page ENGINE 3.3/3.8L DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 76 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 77 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 78 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 80 DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . . . . . . . . 82 DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . 83 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 STANDARD PROCEDURE STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . 84 STANDARD PROCEDURE - FORM-INPLACE GASKETS AND SEALERS . . . . . . . . . 84 STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION . . . . . . . . 85 STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE . . . . . . . . . . . . . . . . . . . . . 86 STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS . . . . . . . . . 86 STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 86 REMOVAL - ENGINE ASSEMBLY . . . . . . . . . . . 87 INSTALLATION - ENGINE ASSEMBLY . . . . . . . . 90 SPECIFICATIONS 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . 92 SPECIFICATIONS - TORQUE . . . . . . . . . . . . 95 SPECIAL TOOLS 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . 96 AIR CLEANER ELEMENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 99 AIR CLEANER HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 100 CYLINDER HEAD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 100 DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 REMOVAL - CYLINDER HEAD . . . . . . . . . . . . 100 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 101 INSTALLATION - CYLINDER HEAD . . . . . . . . . 102 CYLINDER HEAD COVER(S) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 103 CYLINDER HEAD COVER - RIGHT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103 CYLINDER HEAD COVER - LEFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 105 INTAKE/EXHAUST VALVES & SEATS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 105 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 105 STANDARD PROCEDURE - REFACING VALVES AND VALVE SEATS . . . . . . . . . . . . 105 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 106 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107 VALVE SPRINGS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 107 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 107 REMOVAL REMOVAL - CYLINDER HEAD OFF . . . . . . . 108 REMOVAL - CYLINDER HEAD ON . . . . . . . . 108 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 109 INSTALLATION INSTALLATION - CYLINDER HEAD OFF . . . 109 INSTALLATION - CYLINDER HEAD ON . . . . 109 ROCKER ARMS DESCRIPTION DESCRIPTION - ROCKER ARMS . . . . . . . . . 110 DESCRIPTION - PUSHRODS . . . . . . . . . . . . 110 OPERATION OPERATION - ROCKER ARMS . . . . . . . . . . 110 OPERATION - PUSHRODS . . . . . . . . . . . . . 110 REMOVAL - ROCKER ARMS AND SHAFT . . . . 110 DISASSEMBLY - ROCKER ARMS AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 ASSEMBLY - ROCKER ARMS AND SHAFT . . . 111 INSTALLATION - ROCKER ARMS AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 VALVE STEM SEALS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 112 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 113 ENGINE BLOCK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 113 STANDARD PROCEDURE - CYLINDER BORE HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 RS CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 113 CAMSHAFT & BEARINGS (IN BLOCK) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 114 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 114 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 115 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 115 CONNECTING ROD BEARINGS STANDARD PROCEDURE - MEASURING CONNECTING ROD BEARING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . 115 CRANKSHAFT DESCRIPTION DESCRIPTION - 3.3L . . . . . . . . . . . . . . . . . . 116 DESCRIPTION - 3.8L . . . . . . . . . . . . . . . . . . 117 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 117 STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY . . . . . . . . . . . . . . 117 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 118 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 118 CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE - MAIN BEARING FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 REMOVAL - CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 121 INSTALLATION - CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 121 CRANKSHAFT OIL SEAL - FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123 CRANKSHAFT OIL SEAL - REAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123 CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124 FLEX PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124 HYDRAULIC LIFTERS (CAM IN BLOCK) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 125 DIAGNOSIS AND TESTING - HYDRAULIC LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126 PISTON & CONNECTING ROD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 126 STANDARD PROCEDURE STANDARD PROCEDURE - FITTING CONNECTING RODS . . . . . . . . . . . . . . . . . . 127 STANDARD PROCEDURE - FITTING PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 128 ENGINE 3.3/3.8L PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . VIBRATION DAMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . ENGINE MOUNTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . FRONT MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . LEFT MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . REAR MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . RIGHT MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . LUBRICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . OIL STANDARD PROCEDURE STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . STANDARD PROCEDURE - ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . OIL COOLER & LINES DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL FILTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL FILTER ADAPTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ..................... INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL PRESSURE RELIEF VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . 9 - 75 . . . . 130 . . . . 131 . . . . 131 . . . . 132 . . . . 132 . . . . 133 . . . . 133 . . . . 133 . . . . 134 . . . . 134 . . . . 135 . . . . 136 . . . . 137 . . . . 137 . . . . 137 . . . . 137 . . . . 137 . . . . 138 . . . . 139 . . . . . . . . . . . . . 140 . 140 . 140 . 140 . . . . 140 . . . . 140 . . . . 141 . . . . 141 . . . . . . . . . . . . . 141 . 141 . 142 . 142 . . . . 142 . . . . 143 . . . . . . . . . . . . . 143 . 143 . 143 . 143 9 - 76 ENGINE 3.3/3.8L OIL PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . INTAKE MANIFOLD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS . . . . . . . . . . . . . . . . . . INTAKE MANIFOLD - UPPER STANDARD PROCEDURE STANDARD PROCEDURE - MANIFOLD STRIPPED THREAD REPAIR . . . . . . . . . . STANDARD PROCEDURE - INTAKE MANIFOLD VACUUM PORT REPAIR . . . . REMOVAL - UPPER INTAKE MANIFOLD . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... INSTALLATION - UPPER INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . INTAKE MANIFOLD - LOWER REMOVAL - LOWER INTAKE MANIFOLD . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... INSTALLATION - LOWER INTAKE MANIFOLD EXHAUST MANIFOLD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . RS . . . . . . . . 143 . 143 . 144 . 144 . 144 . 146 . 146 . . 146 . . 146 . . 146 . . 146 . . . . . 147 . 147 . 148 . 149 . . 149 . . 150 . . 150 . . 150 . 150 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST MANIFOLD - RIGHT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . EXHAUST MANIFOLD - LEFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ....................... INSTALLATION . . . . . . . . . . . . . . . . . . . . . . VALVE TIMING STANDARD PROCEDURE STANDARD PROCEDURE - VALVE TIMING VERIFICATION . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - MEASURING TIMING CHAIN WEAR . . . . . . . . . . . . . . . TIMING CHAIN COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . TIMING CHAIN AND SPROCKETS REMOVAL REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET . . . . . . . . . . . . . REMOVAL - CRANKSHAFT SPROCKET . INSTALLATION INSTALLATION - CRANKSHAFT SPROCKET . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - TIMING CHAIN AND CAMSHAFT SPROCKET . . . . . . . . . . . . . . . 152 . . . . . 152 . 152 . 153 . 153 . . . . . 154 . 154 . 154 . 154 . . 155 . . 155 . . 155 . . 156 . . 159 . . 159 . . 159 . . 159 . . 152 ENGINE 3.3/3.8L DESCRIPTION The 3.3 Liter (201 cu. in.) and 3.8 Liter (231 cu. in.) engines are 60° V-6 engines with cast iron cylinder blocks and aluminum cylinder heads (Fig. 1). The engine uses a single, block mounted camshaft with pushrods to actuate the valves. These engines do not have provisions for a free wheeling valve train. The firing order is 1–2–3–4–5–6. The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, and 6. The rear cylinder bank is numbered 1, 3, and 5. The engine identification number is located on the rear of the cylinder block just below the cylinder head (Fig. 2). ENGINE 3.3/3.8L RS 9 - 77 ENGINE 3.3/3.8L (Continued) Fig. 1 3.3/3.8L V-6 Engines DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Fig. 2 Engine Identification Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls). Refer to the Engine Mechanical and the Engine Performance diagnostic charts, for possible causes and corrections of malfunctions (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING - MECHANICAL) (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING - PERFORMANCE). For fuel system diagnosis, (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING). Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following: • Cylinder Compression Pressure Test • Cylinder Combustion Pressure Leakage Test • Engine Cylinder Head Gasket Failure Diagnosis • Intake Manifold Leakage Diagnosis • Hydraulic Lash Adjuster Noise Diagnosis • Engine Oil Leak Inspection 9 - 78 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION ENGINE WILL NOT START ENGINE STALLS OR IDLES ROUGH POSSIBLE CAUSE CORRECTION 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 ELECTRICAL/BATTERY SYSTEM DIAGNOSIS AND TESTING) 2. Corroded or loose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to terminals. 3. Faulty starter. 3. Test starting system. (Refer to 8 ELECTRICAL/STARTING DIAGNOSIS AND TESTING) 4. Faulty coil(s) or control unit. 4. Test and replace as needed. (Refer to Appropriate Diagnostic Information) 5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 ELECTRICAL/IGNITION CONTROL - SPECIFICATIONS) 6. Contamination in fuel system. 6. Clean system and replace fuel filter. 7. Faulty fuel pump. 7. Test fuel pump and replace as needed. (Refer to Appropriate Diagnostic Information) 8. Incorrect engine timing. 8. Check for a skipped timing belt/chain. 1. Idle speed too low. 1. Test minimum air flow. (Refer to Appropriate Diagnostic Information) 2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic Information) 3. Intake manifold leakage. 3. Inspect intake manifold, manifold gasket, and vacuum hoses. 4. Faulty ignition coil(s). 4. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) ENGINE 3.3/3.8L RS 9 - 79 ENGINE 3.3/3.8L (Continued) CONDITION ENGINE LOSS OF POWER ENGINE MISSES ON ACCELERATION ENGINE MISSES AT HIGH SPEED POSSIBLE CAUSE CORRECTION 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter. 3. Faulty fuel pump. 3. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 4. Incorrect valve timing. 4. Correct valve timing. 5. Leaking cylinder head gasket. 5. Replace cylinder head gasket. 6. Low compression. 6. Test compression of each cylinder. 7. Burned, warped, or pitted valves. 7. Replace valves. 8. Plugged or restricted exhaust system. 8. Perform exhaust restriction test. (Refer to 11 - EXHAUST SYSTEM DIAGNOSIS AND TESTING) Install new parts, as necessary. 9. Faulty ignition coil(s). 9. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 1. Dirty or incorrectly gapped spark plugs. 1. Clean spark plugs and set gap. 2. Contamination in Fuel System. 2. Clean fuel system and replace fuel filter. 3. Burned, warped, or pitted valves. 3. Replace valves. 4. Faulty ignition coil(s). 4. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap. 2. Faulty ignition coil(s). 2. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 3. Dirty fuel injector(s). 3. Test and replace as necessary. (Refer to Appropriate Diagnostic Information) 4. Contamination in fuel system. 4. Clean system and replace fuel filter. 9 - 80 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION NOISY VALVES POSSIBLE CAUSES CORRECTION 1. High or low oil level in crankcase. 1. Check and correct engine oil level. 2. Thin or diluted oil. 2. Change oil to correct viscosity. 3. Thick oil 3. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. CONNECTING ROD NOISE 4. Low oil pressure. 4. Check and correct engine oil pressure problem. 5. Dirt in hydraulic lifters/lash adjusters. 5. Replace hydraulic lifters/lash adjusters. 6. Worn rocker arms. 6. Inspect oil supply to rocker arms. 7. Worn hydraulic lifters/lash adjusters. 7. Replace hydraulic lifters/lash adjusters. 8. Worn valve guides. 8. Replace cylinder head assembly. 9. Excessive runout of valve seats on valve faces. 9. Grind valve seats and valves. 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Thin or diluted oil. 3. Change oil to correct viscosity. 4. Thick oil 4. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. 5. Excessive bearing clearance. 5. Measure bearings for correct clearance. Repair as necessary. 6. Connecting rod journal out-of-round. 6. Replace crankshaft or grind surface. 7. Misaligned connecting rods. 7. Replace bent connecting rods. ENGINE 3.3/3.8L RS 9 - 81 ENGINE 3.3/3.8L (Continued) CONDITION MAIN BEARING NOISE POSSIBLE CAUSES CORRECTION 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Thin or diluted oil. 3. Change oil to correct viscosity. 4. Thick oil 4. (a) Change engine oil and filter. (b) Run engine to operating temperature. (c) Change engine oil and filter again. OIL PRESSURE DROP OIL LEAKS 5. Excessive bearing clearance. 5. Measure bearings for correct clearance. Repair as necessary. 6. Excessive end play. 6. Check thrust bearing for wear on flanges. 7. Crankshaft journal out-of-round or worn. 7. Replace crankshaft or grind journals. 8. Loose flywheel or torque converter. 8. Tighten to correct torque. 1. Low oil level. 1. Check engine oil level. 2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/ switch. 3. Low oil pressure. 3. Check oil pressure sensor/switch and main bearing oil clearance. 4. Clogged oil filter. 4. Install new oil filter. 5. Worn parts in oil pump. 5. Replace worn parts or pump. 6. Thin or diluted oil. 6. Change oil to correct viscosity. 7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean, or replace. 8. Oil pump suction tube loose. 8. Remove oil pan and install new tube or clean, if necessary. 9. Oil pump cover warped or cracked. 9. Install new oil pump. 10. Excessive bearing clearance. 10. Measure bearings for correct clearance. 1. Misaligned or deteriorated gaskets. 1. Replace gasket(s). 2. Loose fastener, broken or porous metal part. 2. Tighten, repair or replace the part. 3. Misaligned or deteriorated cup or threaded plug. 3. Replace as necessary. 9 - 82 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) CONDITION OIL CONSUMPTION OR SPARK PLUGS FOULED POSSIBLE CAUSES CORRECTION 1. PCV system malfunction. 1. Check system and repair as necessary. (Refer to 25 EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new rings. 3. Carbon in oil ring slots. 3. Install new rings. 4. Rings fitted too tightly in grooves. 4. Remove rings and check grooves. If groove is not proper width, replace piston. 5. Worn valve guide(s). 5. Replace cylinder head assembly. 6. Valve stem seal(s) worn or damaged. 6. Replace seal(s). DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed: (1) Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak. (2) Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light. (3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair as necessary. (4) If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection. (5) If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows: • Disconnect the fresh air hose (make-up air) at the cylinder head cover and plug or cap the nipple on the cover. • Remove the PCV valve hose from the cylinder head cover. Cap or plug the PCV valve nipple on the cover. • Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure. • Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provides the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures. • If the leakage occurs at the crankshaft rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak. (6) If no leaks are detected, turn off the air supply. Remove the air hose, all plugs, and caps. Install the PCV valve and fresh air hose (make-up air). Proceed to next step. (7) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light. NOTE: If oil leakage is observed at the dipstick tube to block location; remove the tube, clean and reseal using MoparT Stud & Bearing Mount (press fit tube applications only), and for O-ring style tubes, remove tube and replace the O-ring seal. INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: (1) Disconnect the battery. (2) Raise the vehicle. RS ENGINE 3.3/3.8L 9 - 83 ENGINE 3.3/3.8L (Continued) (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area, remove transmission for further inspection. (a) Circular spray pattern generally indicates seal leakage or crankshaft damage. (b) Where leakage tends to run straight down, possible causes are a porous block, oil gallery cup plug, bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items. (4) If no leaks are detected, pressurize the crankcase as previously described. CAUTION: Do not exceed 20.6 kPa (3 psi). (5) If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. (6) For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. (7) After the oil leak root cause and appropriate corrective action have been identified, replace component(s) as necessary. DIAGNOSIS AND TESTING - 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 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. (4) Remove the Auto Shutdown (ASD) relay from the PDC. (5) Be sure throttle blade is fully open during the compression check. (6) Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0–500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRBIIIt. For Special Tool identification, (Refer to 9 - ENGINE - SPECIAL TOOLS). (7) Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. (8) Repeat the previous step for all remaining cylinders. (9) Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. (10) If one or more cylinders have abnormally low compression pressures, repeat the compression test. (11) 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. DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: • Exhaust and intake valve leaks (improper seating). • Leaks between adjacent cylinders or into water jacket. • Any causes for combustion/compression pressure loss. WARNING: DO NOT REMOVE THE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Check the coolant level and fill as required. DO NOT install the pressure cap. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF. Clean spark plug recesses with compressed air. Remove the spark plugs. Remove the oil filler cap. Remove the air cleaner. 9 - 84 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) Calibrate the tester according to the manufacturer’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum, with 552 kPa (80 psi) recommended. Perform the test procedures on each cylinder according to the tester manufacturer’s instructions. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the coolant. All gauge pressure indications should be equal, with no more than 25% leakage per cylinder. FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder. (3) Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. 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 9 - ENGINE - SPECIFICATIONS). Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. STANDARD PROCEDURE (4) Install the proper crankshaft bearings to achieve the specified bearing clearances. STANDARD PROCEDURE - 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 across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 in.) off center and away from the oil holes (Fig. 3). (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. Fig. 3 Plastigage Placed in Lower Shell—Typical 1 - PLASTIGAGE NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-inplace gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other. MOPARt ENGINE RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPARt ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. RS ENGINE 3.3/3.8L 9 - 85 ENGINE 3.3/3.8L (Continued) MOPARt GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges. MOPARt BED PLATE SEALANT is a unique (green-in-color) anaerobic type gasket material that is specially made to seal the area between the bedplate and cylinder block without disturbing the bearing clearance or alignment of these components. The material cures slowly in the absence of air when torqued between two metallic surfaces, and will rapidly cure when heat is applied. MOPARt GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multilayer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator. SEALER APPLICATION Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopart Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets. STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. Never use the following to clean gasket surfaces: • Metal scraper • Abrasive pad or paper to clean cylinder block and head • High speed power tool with an abrasive pad or a wire brush (Fig. 4) NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Only use the following for cleaning gasket surfaces: • Solvent or a commercially available gasket remover • Plastic or wood scraper (Fig. 4) • Drill motor with 3M Roloc™ Bristle Disc (white or yellow) (Fig. 4) CAUTION: Excessive pressure or high RPM (beyond the recommended speed), can damage the sealing surfaces. The mild (white, 120 grit) bristle disc is recommended. If necessary, the medium (yellow, 80 grit) bristle disc may be used on cast iron surfaces with care. Fig. 4 Proper Tool Usage For Surface Preparation 1 - ABRASIVE PAD 2 - 3M ROLOC™ BRISTLE DISC 3 - PLASTIC/WOOD SCRAPER 9 - 86 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE CAUTION: Be sure that the tapped holes maintain the original center line. When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. Heli-Coil tools and inserts are readily available from automotive parts jobbers. CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur. (1) Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of foreign material. (2) Remove negative battery cable. (3) Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure. (4) With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket. (5) Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other). (6) Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.) (7) Repair engine or components as necessary to prevent this problem from re-occurring. STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug (Fig. 5). CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. (8) Install new spark plugs. (9) Drain engine oil and remove oil filter. (10) Install a new oil filter. (11) Fill engine with specified amount of approved oil. (12) Connect negative battery cable. (13) Start engine and check for any leaks. STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be repaired. Essentially, this repair consists of drilling out worn or damaged threads, tapping the hole with a special Heli-Coil Tap, (or equivalent) and installing an insert into the tapped hole. This brings the hole back to its original thread size. Fig. 5 Core Hole Plug Removal 1 2 3 4 5 - CYLINDER BLOCK REMOVE PLUG WITH PLIERS STRIKE HERE WITH HAMMER DRIFT PUNCH CUP PLUG CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems. Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopart Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer. It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately. ENGINE 3.3/3.8L RS 9 - 87 ENGINE 3.3/3.8L (Continued) REMOVAL - ENGINE ASSEMBLY (1) Perform fuel pressure release procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE). (2) Disconnect negative battery cable. (3) Remove air cleaner and hoses. (4) Disconnect the fuel line from fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE). (5) Remove the wiper module (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (6) Block off heater hoses to the rear heater system using pinch-off pliers (if equipped). (7) Drain the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). (8) Disconnect the heater hoses. (9) Remove the radiator upper support crossmember (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - REMOVAL). (10) Remove the radiator fans (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL). (11) Disconnect the throttle cables from the throttle body. (12) Disconnect the MAP, IAC, and TPS electrical connectors. (13) Disconnect the EGR transducer electrical connector (if equipped). (14) Disconnect the vacuum hoses from throttle body. (15) Disconnect the brake booster and speed control vacuum hoses. (16) Disengage wire harness clip from the right side engine mount. (17) Remove the power steering reservoir from mounting position and set aside. Do not disconnect hose. (18) Disconnect ground strap from rear of cylinder head. (19) Disconnect engine coolant temperature (ECT) sensor and ignition coil electrical connectors. (20) Disconnect the fuel injector electrical harness connector and disengage clip from support bracket. (21) Disconnect camshaft and crankshaft position sensor electrical connectors. (22) Evacuate air conditioning system. Refer to 24 - HEATING & AIR CONDITIONING. (23) Disconnect A/C compressor electrical connector. (24) Disconnect the A/C lines from compressor. Cover and seal all openings of hoses and compressor. (25) Remove the radiator upper hose. (26) Disengage electrical harness clip at transaxle dipstick tube. (27) Remove transaxle dipstick tube. Seal opening using a suitable plug. NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the transaxle, damage to the inner wall of the hose will occur. To prevent prevent potential leakage, the cooler hoses must be cut off flush at the transaxle fitting, and a service cooler hose splice kit must be installed upon reassembly. (28) Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with fittings. Plug cooler lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly. (29) Disconnect transaxle shift linkage and electrical connectors. (30) Raise vehicle on hoist and drain the engine oil. (31) Remove the axle shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) (32) Remove crossmember cradle plate (Fig. 6). Fig. 6 Crossmember Cradle Plate 1 - CRADLE PLATE 9 - 88 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) (33) AWD equipped: Remove the power transfer unit (PTU) (Refer to 21 - TRANSMISSION/TRANSAXLE/POWER TRANSFER UNIT - REMOVAL). (34) Disconnect exhaust pipe from the manifold (Fig. 7). Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER Fig. 7 Catalytic Converter to Exhaust Manifold 1 2 3 4 - FLAG NUT GASKET BOLT CATALYTIC CONVERTER (35) Remove front engine mount and bracket as an assembly. (36) Remove the engine rear mount bracket. (37) Remove the engine to transaxle struts (Fig. 8). (38) Remove transaxle case cover (Fig. 8). (39) Remove flex plate to torque converter bolts. Mark torque converter to flex plate for orientation for reassembly. (40) Remove the power steering pressure hose support clip attaching bolt. (41) Disconnect the knock sensor electrical connector (3.8L only). 1 2 3 4 5 6 7 8 9 - BRACKET - ENGINE REAR MOUNT BOLT - TRANSAXLE CASE COVER STRUT - TRANSAXLE TO ENGINE HORIZONTAL BOLT - HORIZONTAL STRUT BOLT - STRUT TO TRANSAXLE COVER - TRANSAXLE CASE LOWER STRUT - TRANSAXLE TO ENGINE BOLT - STRUT TO ENGINE BOLT - ENGINE REAR MOUNT BRACKET (42) Disconnect the engine block heater electrical connector (if equipped). (43) Remove the accessory belt splash shield. (44) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (45) Disconnect the radiator lower hose. (46) Remove air conditioning compressor from engine. (47) Remove the generator (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - REMOVAL). ENGINE 3.3/3.8L RS 9 - 89 ENGINE 3.3/3.8L (Continued) (48) Remove the water pump pulley attaching bolts and position pulley between pump hub and housing. (49) Disconnect the oil pressure switch electrical connector. (50) Disconnect wiring harness support clip from engine oil dipstick tube. (51) Install Special Tools 6912 and 8444 Adapters on the right side (rear) of engine block (Fig. 9). Fig. 10 Positioning Special Tool 6848 for use with Adapters 8444 & 6912 1 - SLOTS 2 - SPECIAL TOOLS 6848 Fig. 9 ADAPTER TOOLS MOUNTED ON BLOCK 1 - SPECIAL TOOL 6912 2 - SPECIAL TOOL 8444 (52) Lower the vehicle. (53) Remove the power steering pump and set aside. (54) Raise vehicle enough to allow engine dolly Special Tool 6135 and cradle Special Tool 6710 with post Special Tool 6848 and adaptor Special Tool 6909 to be installed under vehicle (Fig. 12). (55) Loosen cradle/post mounts to allow movement for positioning posts into locating holes on the engine (Fig. 10) and (Fig. 11). Slowly lower vehicle and position cradle/post mounts until the engine is resting on posts. Tighten all cradle/post mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission. Fig. 11 Special Tools 6848 with Adapters 6909 1 2 3 4 - OIL FILTER SPECIAL TOOLS 6909 OIL PAN SPECIAL TOOLS 6848 (56) Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION is on the cradle. (57) Install and secure the safety straps to the cradle fixture and around the engine (Fig. 12). (58) Remove the engine right side mount to engine attaching bolts (Fig. 13). (59) Remove the left mount through bolt (Fig. 14). (60) Raise vehicle slowly. It is necessary to move the engine/transmission assembly with the dolly to allow for removal around body flanges. 9 - 90 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) Fig. 12 Positioning Engine Cradle Support Post Mounts 1 2 3 4 - SPECIAL TOOL 8444 SPECIAL TOOLS 6848 SPECIAL TOOL 6912 SPECIAL TOOLS 6135 & 6710 INSTALLATION - ENGINE ASSEMBLY (1) Position engine and transmission assembly under vehicle. Slowly lower the vehicle down over the engine and transmission. It is necessary to move the engine/transmission assembly with the dolly for clearance around body flanges. (2) Align engine and transmission mounts to attaching points. Install mounting bolts at the right engine mount (Fig. 13) and left transmission mount (Fig. 14). (3) Remove the safety straps from around engine. (4) Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135, 6710, 6848 and 6909 (Fig. 12). (5) Remove Special Tools 6912 and 8444 (Fig. 9). (6) Lower the vehicle. (7) Install power steering pump and pressure line support. 5 - SPECIAL TOOLS 6848 6 - SAFETY STRAPS 7 - SPECIAL TOOLS 6909 (8) Install the generator and wiring harness (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR INSTALLATION). (9) Raise vehicle. (10) Attach wiring harness support clip to the engine oil dipstick tube. (11) Connect oil pressure switch electrical connector. (12) Install the A/C compressor. (13) Install the water pump pulley. (14) Connect the radiator lower hose. (15) Install the accessory drive belt and splash shield (Refer to 7 - COOLING/ACCESSORY DRIVE/ DRIVE BELTS - INSTALLATION). (16) Connect the engine block heater electrical connector (if equipped). (17) Connect the knock sensor electrical connector (3.8L only). (18) Install the torque converter to flex plate bolts. (19) Install the transaxle case cover (Fig. 8). ENGINE 3.3/3.8L RS 9 - 91 ENGINE 3.3/3.8L (Continued) Fig. 13 Right Mount to Engine 1 - BOLT 2 - MOUNT BRACKET 3 - ENGINE RIGHT MOUNT ASSEMBLY Fig. 14 LEFT MOUNT TO FRAME BRACKET 1 2 3 4 - FRAME BRACKET FRAME RAIL - LEFT BOLT TRANSAXLE MOUNT (20) Install the powertrain struts (Fig. 8). (21) Install the engine rear mount bracket. (22) Install the engine front mount and bracket assembly. (23) AWD equipped; Install the power transfer unit (PTU) (Refer to 21 - TRANSMISSION/TRANSAXLE/POWER TRANSFER UNIT - INSTALLATION). (24) Install the axle shafts (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION). (25) Connect exhaust pipe to manifold (Fig. 7). (26) Install crossmember cradle plate (Fig. 6). (27) Lower vehicle. (28) Connect transaxle shift linkage. (29) Connect transaxle electrical connectors. (30) Remove plugs from transmission cooler hoses and install transaxle oil cooler line service splice kit. Refer to instructions included with kit. (31) Install transaxle dipstick tube and attach electrical harness clip. (32) Connect the A/C lines to compressor. (33) Connect the A/C compressor electrical connector. (34) Evacuate and recharge A/C system. (35) Connect crankshaft and camshaft position sensors. (36) Connect the fuel injector electrical harness connector and engage clip to support bracket. (37) Connect engine coolant temperature (ECT) sensor and ignition coil electrical connectors. (38) Connect the ground strap to rear of cylinder head. (39) Install power steering reservoir. (40) Engage wire harness clip to engine right side mount. (41) Connect the brake booster and speed control vacuum hoses. (42) Connect the vacuum hoses to the throttle body. (43) Connect the EGR transducer electrical connector (if equipped). (44) Connect the TPS, IAC, and MAP sensor electrical connectors. (45) Connect throttle cables to throttle body. (46) Install the radiator fans (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION). (47) Connect the radiator upper hose. (48) Connect the heater hoses. Remove pinch-off pliers from the rear heater hoses (if equipped). (49) Install the radiator upper support crossmember (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - INSTALLATION). (50) Install the wiper module (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (51) Connect the fuel line to fuel rail (Refer to 14 FUEL SYSTEM/FUEL DELIVERY/FUEL LINES STANDARD PROCEDURE). (52) Install the air cleaner and hoses. (53) Install new oil filter. Fill engine crankcase with proper oil to correct level. (54) Connect negative cable to battery. (55) Fill the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). (56) Start engine and run until operating temperature is reached. (57) Adjust transmission linkage, if necessary. 9 - 92 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) SPECIFICATIONS DESCRIPTION 3.3/3.8L ENGINE DESCRIPTION SPECIFICATION 60° V-6 Engine Number of Cylinders 6 Displacement —3.3L Out-of-Round (Service Limits) (0.003 in.) Taper (Service Limits) 0.051 mm Lifter Bore Diameter 22.980–23.010 mm (0.905–0.906 in.) Deck Surface Flatness (Max.) 3.3 Liters (201 cu. in.) —3.8L 3.8 Liters (231 cu. in.) Bore —3.3L 93.0 mm (3.66 in.) —3.8L 0.076 mm (0.002 in.) General Specification Type SPECIFICATION 96.0 mm (3.779 in.) Stroke 0.1 mm (0.004 in.) Pistons Piston Diameter —3.3L —Measured 39.8 mm (1.567 in.) from piston top 92.968–92.998 mm —3.8L —Measured 33.01 mm (1.30 in.) from piston top 95.968–95.998 mm Clearance in Bore @ Size Location (New) (3.660–3.661 in.) (3.778–3.779 in.) -0.005–0.039 mm (-0.0002–0.0015 in.) Weight —3.3L 81.0 mm —3.3L (3.188 in.) —3.8L 362 ±5 grams (12.77 ±0.1764 oz.) 87.0 mm —3.8L (3.425 in.) 426 ±5 grams (15.03 ±0.1764 oz.) Compression Ratio Piston Pins —3.3L 9.35:1 —3.8L 9.6:1 Firing Order Type Press Fit in Rod (Serviced as an Assembly) Clearance in Piston @ 21° C (70° F) 0.006–0.019 mm 1-2-3-4-5-6 Cylinder Number (Front to Rear) —Front Bank 2,4,6 —Rear Bank 1,3,5 Compression Pressure— Minimum 689.5 kPa Clearance in Connecting Rod (Interference Fit) Diameter 22.87–22.88 mm (0.9007–0.9009 in.) (100 psi) Max. Variation Between Cylinders 25% Length —3.3L —3.8L Cylinder Bore Diameter (Standard) 71.25–71.75 (2.805–2.824 in.) 92.993–93.007 mm (3.661–3.6617 in.) —3.8L 67.25–67.75 mm (2.648–2.667 in.) Cylinder Block —3.3L (0.0002–0.0007 in.) 95.993–96.007 mm (3.7792–3.780 in.) Piston Rings Ring End Gap—Top Compression Ring Wear Limit 0.18–0.38 mm (0.007–0.015 in.) 1.0 mm (0.039 in.) ENGINE 3.3/3.8L RS 9 - 93 ENGINE 3.3/3.8L (Continued) DESCRIPTION Ring End Gap—2nd Compression Ring Wear Limit SPECIFICATION DESCRIPTION SPECIFICATION 0.28–0.57 mm (0.017–0.020 in.) (0.011–0.022 in.) 1.0 mm Connecting Rod Bearing Clearance 0.019–0.065 mm (0.039 in.) Ring End Gap—Oil Control Steel Rails (0.0008–0.0026 in.) 0.23–0.78 mm Wear Limit 0.074 mm (0.009–0.030 in.) Wear Limit 1.88 mm (0.003 in.) Side Clearance 0.13–0.32 mm (0.074 in.) (0.005–0.013 in.) Ring Side Clearance— Top Compression Ring —3.3L Wear Limit (0.015 in.) 0.030–0.080 mm (0.0012–0.0031 in.) —3.8L 0.030–0.069 mm (0.0012–0.0027 in.) Wear Limit 0.10 mm (0.004 in.) Ring Side Clearance— 2nd Compression Ring —3.3L 0.38 mm Crankshaft Material Nodular Iron Connecting Rod Journal Diameter Main Bearing Journal Diameter 57.979–58.005 mm (2.2827–2.2837 in.) 63.993–64.013 mm (2.5194–2.5202 in.) Journal Out-of-Round (Max.) 0.030–0.095 mm 0.025 mm (0.001 in.) Journal Taper (Max.) 0.025 mm (0.001 in.) (0.0012–0.0037 in.) —3.8L 0.041–0.085 mm End Play 0.09–0.24 mm (0.0036–0.0095 in.) (0.0016–0.0033 in.) Wear Limit 0.13 mm Wear Limit 0.381 mm (0.015 in.) (0.005 in.) Ring Side Clearance—Oil Ring Pack Wear Limit 0.039–0.200 mm (0.0015–0.0078 in.) 0.266 mm Main Bearing Diametrical Clearance —No. 1, 2, 3, 4 0.011–0.055 mm (0.0005–0.0022 in.) (0.009 in.) Wear Limit Ring Width—Top Compression Ring 0.076 mm (0.003 in.) —3.3L 1.46–1.49 mm (0.0575–0.058 in.) —3.8L Camshaft Journal Diameter 1.175–1.190 mm No.1 (0.0462–0.0468 in.) Ring Width—2nd Compression Ring —3.3/3.8L (1.997–1.999 in.) 1.46–1.49 mm No.2 No.3 Ring Width—Oil Ring (Steel Rails) 49.936–49.987 mm (1.9659–1.9679 in.) No.4 0.435–0.490 mm (0.017–0.019 in.) —3.8L 50.317–50.368 mm (1.9809–1.9829 in.) (0.0575–0.058 in.) —3.3L 50.724–50.775 mm 0.435–0.510 mm 49.530–49.581 mm (1.9499–1.9520 in.) Bearing Clearance— Diametrical 0.025–0.101 mm (0.001–0.004 in.) 9 - 94 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) DESCRIPTION SPECIFICATION Bearing Clearance (Max. allowable) 0.127 mm End Play (0.005 in.) 0.254–0.508 mm (0.010–0.020 in.) (Max. allowable) 0.304 mm (0.012 in.) Camshaft Bearing Diameter DESCRIPTION SPECIFICATION Valve Seat Angle 44.5–45° Valve Seat Runout (Service Limits) 0.0762 mm (0.003 in.) Valve Seat Width—Intake & Exhaust 1.50–2.00 mm (0.057–0.078 in.) Valve Guide No. 1 50.800–50.825 mm Guide Bore Diameter (Std.) (1.9999–2.0009 in.) No. 2 50.393–50.419 mm (1.9839–1.9849 in.) No. 3 6.975–7.00 mm (0.274–0.275 in.) Valves Valve Lift (Zero Lash)—Intake & Exhaust 50.013–50.038 mm —3.3L 9.80 mm (1.9690–1.9699 in.) No. 4 (0.385 in.) 49.606–49.632 mm —3.8L 11.0 mm (1.9529–1.954 in.) Exhaust Valve Timing (0.433 in.) Face Angle—Intake 45–45.5° Closes—3.3L (ATDC) 13° Face Angle—Exhaust Closes—3.8L (ATDC) 18° Head Diameter—Intake Opens—3.3L (BBDC) 43° Opens—3.8L (BBDC) 46° Duration—3.3L 236° Duration—3.8L 244° Intake Valve Timing 52° Closes—3.8L (ABDC 63° Opens—3.3L (ATDC) 6° Opens—3.8L (ATDC) 1° Duration—3.3L 226° Duration—3.8L 242° Valve Overlap—3.3L 7° Valve Overlap—3.8L 17° Lifters Type Diameter O.D. 22.949–22.962 mm 0.020–0.061 mm 0.0007–0.0024 in.) Cylinder Head Gasket Thickness (Compressed) Head Diameter—Exhaust 35.37–35.63 mm (1.39–1.40 in.) Valve Margin 0.825–0.973 mm (0.032–0.038 in.) Exhaust 1.565–1.713 mm (0.061–0.067 in.) Valve Length (Overall) Intake 125.84–126.6 mm (4.95–4.98 in.) Exhaust 127.2–127.96 mm (5.00–5.04 in.) Valve Stem Tip Height Hydraulic Roller (0.903–0.904 in.) Clearance In Block (1.88–1.89 in.) Intake Closes—3.3L (ABDC 45–45.5° 47.87–48.13 mm 0.65–0.75 mm (0.025–0.029 in.) Intake (valve tip to spring seat washer) Exhaust (valve tip to spring seat washer) 48.1–49.7 mm (1.89–1.95 in.) 48.53–50.09 mm (1.91–1.97 in.) Valve Stem Diameter Intake (Standard) 6.935–6.953 mm (0.2730–0.2737 in.) ENGINE 3.3/3.8L RS 9 - 95 ENGINE 3.3/3.8L (Continued) DESCRIPTION SPECIFICATION Exhaust (Standard) DESCRIPTION SPECIFICATION 6.906–6.924 mm (0.2718–0.2725 in.) Valve Stem to Guide Clearance Intake (3.148 in.) Tip Clearance Between Rotors (Max.) 0.025–0.065 mm (0.001–0.0025 in.) Max. Allowable (Rocking Method) 0.247 mm (0.010 in.) Exhaust 0.059–0.094 mm (0.002–0.0037 in.) Max. Allowable (Rocking Method) 0.414 mm (0.016 in.) Push Rods Length 135.438 mm (5.33 in.) Valve Springs Free Length (Approx.) 51.4 mm (2.02 in.) Wire Diameter (0.008 in.) Oil Pressure 34.47 kPa At Curb Idle Speed* (Minimum with engine at operating temerature) (5 psi) At 3000 rpm 205–551 kPa (30–80 psi) Oil Filter By-pas Valve Setting 62–103 kPa Oil Pressure Switch Actuating Pressure 14–28 kPa (9–15 psi) (2–4 psi) caution: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. SPECIFICATIONS - TORQUE 3.95–4.77 mm (0.15–0.19 in.) Number of Coils 7.52 Spring Tension (Valve Closed) 376.4–424.4 N @ 41.9 mm (84.6–95.6 lbs. @ 1.65 in.) Installed Height DESCRIPTION N·m Ft. Lbs. In. Lbs. Camshaft Sprocket—Bolt 54 40 — Camshaft Thrust Plate—Bolts 12 — 105 Connecting Rod Cap—Bolts 54 +1⁄4 turn 40 +1⁄4 turn — Crankshaft Main Bearing Cap—Bolts 41 +1⁄4 turn 30 +1⁄4 turn — Crankshaft Main Bearing Cap Cross Bolts (3.8L) 61 45 — Crankshaft Oil Seal Retainer Rear—Bolts 12 — 105 41.1–42.7 mm (1.61–1.68 in.) Oil Pump Clearance Over Rotors—Inner and Outer (Max.) (0.004 in.) Cover Out-of-Flat (Max.) 0.025 mm 0.10 mm (0.001 in.) Inner Rotor Thickness (Min.) 7.64 mm (0.301 in.) Outer Rotor Thickness (Min.) Outer Rotor Clearance (Max.) Crankshaft Damper—Bolt 54 40 — Cylinder Block Drain Plugs 20 15 — Cylinder Head—Bolts (Refer to 9 - ENGINE/ CYLINDER HEAD INSTALLATION) Cylinder Head Cover— Bolts 12 — 105 Flex Plate to Crankshaft 95 70 — Engine Mounting (Refer to 9 - ENGINE/ ENGINE MOUNTING) Exhaust Manifold—Bolts 23 7.64 mm (0.301 in.) 0.039 mm (0.015 in.) Outer Rotor Diameter (Min.) 0.20 mm 79.95 mm — 200 9 - 96 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) N·m Ft. Lbs. In. Lbs. Exhaust Crossover Pipe—Bolts 54 40 — Intake Manifold Lower—Bolts 23 — 200 Intake Manifold - Lower Gasket Retainer—Bolts 12 — 105 Intake Manifold Upper—Bolts 12 — 105 Lifter Yoke Retainer— Bolts 12 — 105 Oil Filter Attaching Fitting 54 40 — Oil Cooler Attaching Fitting 27 20 — Oil Filter 20 15 — Oil Filter Adapter—Bolts 28 — 250 Oil Gallery Plug 27 20 — Oil Pan—Bolts 12 — 105 Oil Pan Drain—Plug 27 20 — Oil Pressure Switch 23 — 200 Oil Pump Cover Plate—Screws 12 — 105 Oil Pump Pick-up Tube—Bolt 28 — 250 Oil Dipstick Housing— Bolts 48 35 — DESCRIPTION SPECIAL TOOLS 3.3/3.8L ENGINE Dolly 6135 Rocker Arm Shaft—Bolts 23 — 200 Spark Plug 16 12 — —M8 Bolt 27 20 — —M10 Bolt Timing Chain Case Cover 54 40 — Water Pump—Bolts 12 — 105 Water Pump Pulley— Bolts 28 — 250 Cradle 6710A Adapter 6909A Adapter 8444 ENGINE 3.3/3.8L RS 9 - 97 ENGINE 3.3/3.8L (Continued) Indicator, Cylinder Bore C-119 Adapter 6912 Tester - Valve Spring C-647 Puller 1026 Compressor, Valve Spring In-vehicle 8453 Insert, Crankshaft 8450 Valve Spring Compressor Off-vehicle C-3422-D Crankshaft Damper/Sprocket Installer 8452 9 - 98 ENGINE 3.3/3.8L RS ENGINE 3.3/3.8L (Continued) Remover and Installer, Crankshaft Main Bearing C-3059 Adapter, Valve Spring Compressor Off-vehicle 8464 Rear Crankshaft Oil Seal Installer 6926 Remover, Valve Tappet C-4129-A Oil Pressure Gauge C-3292 Remover, Crankshaft Front Seal 6341A Adapter 8406 Installer, Crankshaft Front Seal C-4992 Cooling System Tester 7700 Combustion Leak Tester C-3685-A ENGINE 3.3/3.8L RS 9 - 99 ENGINE 3.3/3.8L (Continued) Pressure Transducer CH7059 Fig. 15 AIR BOX COVER AIR CLEANER HOUSING Compression Test Adapter 8116 REMOVAL (1) Disconnect the negative battery cable. (2) Disconnect the inlet air temperature sensor (Fig. 16). DRB IIIT with PEP Module OT-CH6010A AIR CLEANER ELEMENT REMOVAL (1) Unsnap 2 clips. (2) Lift cover and pull toward the engine and remove cover tabs from air box. (3) Lift cover and remove the element (Fig. 15). INSTALLATION (1) Install the air filter element into air box (Fig. 15). (2) Move cover so that the tabs insert into the air box. (3) Push cover down and snap the 2 clips. Fig. 16 Inlet Air Temperature Sensor (3) (4) cross (5) pin. (6) Remove the inlet hose to throttle body. Remove the bolt for air box at upper radiator member. Pull air box up and off over the single locating Remove air box from vehicle 9 - 100 ENGINE 3.3/3.8L RS AIR CLEANER HOUSING (Continued) INSTALLATION CYLINDER-TO-CYLINDER LEAKAGE TEST (1) Install air box into vehicle and onto the locating pin. (2) Install bolt to hold air box to the upper radiator cross member. (3) Install the inlet hose to the throttle body. (4) Connect the inlet air temperature sensor (Fig. 16). (5) Connect the negative battery cable. To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50–70% reduction in compression pressure. CYLINDER HEAD WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP REMOVED. DESCRIPTION The aluminum cylinder heads (Fig. 17) are designed to create high flow combustion chambers to improve performance, while minimizing the change to the burn rate in the chamber. The cylinder head incorporates the combustion chamber. Two valves per-cylinder are used with inserted valve seats and guides. A multi-layer steel (MLS) type gasket is used between the cylinder head and engine block. OPERATION The cylinder head closes the combustion chamber, allowing the pistons to compress the fuel/air mixture for ignition. The valves are actuated by the lobe profiles on the camshaft to open and close at specified duration to either allow clean air in the combustion chamber or the exhaust gases out; depending on the stroke of the engine. DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. Possible indications of the cylinder head gasket leaking between adjacent cylinders are: • Loss of engine power • Engine misfiring • Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: • Engine overheating • Loss of coolant • Excessive steam (white smoke) emitting from exhaust • Coolant foaming CYLINDER-TO-WATER JACKET LEAKAGE TEST VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. COOLING SYSTEM TESTER METHOD WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident. CHEMICAL TEST METHOD Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit. REMOVAL - CYLINDER HEAD (1) Drain the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Disconnect negative cable from battery. (3) Remove upper and lower intake manifolds. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL) WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE. ENGINE 3.3/3.8L RS 9 - 101 CYLINDER HEAD (Continued) Fig. 17 Cylinder Head and Components 1 2 3 4 - VALVE LOCKS RETAINERS VALVE SPRINGS VALVE STEM SEALS (4) Remove the cylinder head covers. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) (5) Remove the spark plugs from cylinder head. (6) Remove the dipstick and tube (Fig. 18). (7) Remove exhaust manifold(s). (Refer to 9 ENGINE/MANIFOLDS/EXHAUST MANIFOLD REMOVAL) (8) Remove rocker arm and shaft assemblies.(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS REMOVAL) Remove push rods and mark positions to ensure installation in original locations. (9) Remove the eight head bolts from each cylinder head and remove cylinder heads (Fig. 22). CLEANING To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. 5 6 7 8 - SPRING SEATS CYLINDER HEAD VALVE - EXHAUST VALVE - INTAKE NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCEDURE). Be careful not to gouge or scratch the aluminum head sealing surface. Clean all engine oil passages. INSPECTION (1) Before cleaning, check for leaks, damage and cracks. (2) Clean cylinder head and oil passages. (3) Check cylinder head for flatness (Fig. 19). (4) Cylinder head must be flat within: • Standard dimension = less than 0.05 mm (0.002 inch.) • Service Limit = 0.2 mm (0.008 inch.) • Grinding Limit = Maximum of 0.2 mm (0.008 inch.) is permitted. 9 - 102 ENGINE 3.3/3.8L RS CYLINDER HEAD (Continued) (2) Position new gasket(s) on engine block (Fig. 20). The left bank gasket is identified with the “L” stamped in the exposed area of the gasket located at front of engine (shown in (Fig. 20)). The right bank gasket is identified with a “R” stamped in the exposed area of the gasket also, but is located at the rear of the engine. Fig. 20 Head Gasket Installation Fig. 18 DIPSTICK & TUBE 1 - DIPSTICK 2 - BOLT 3 - TUBE CAUTION: 0.20 mm (0.008 in.) MAX is a combined total dimension of the stock removal limit from cylinder head and block top surface (Deck) together. 1 - CYLINDER HEAD GASKET 2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT BANK) (3) The cylinder head bolts are torqued using the torque yield method, they should be examined BEFORE reuse. If the threads are necked down, the bolts must be replaced (Fig. 21). (4) Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced. Fig. 21 Checking Bolts for Stretching (Necking) Fig. 19 Checking Cylinder Head Flatness—Typical INSTALLATION - CYLINDER HEAD (1) Clean all sealing surfaces of engine block and cylinder heads. (Refer to 9 - ENGINE - STANDARD PROCEDURE) 1 2 3 4 - STRETCHED BOLT THREADS ARE NOT STRAIGHT ON LINE THREADS ARE STRAIGHT ON LINE UNSTRETCHED BOLT (5) Tighten the cylinder head bolts 1–8 in the sequence shown in (Fig. 22). Using the 4 step torque turn method, tighten according to the following values: • Step 1: Bolts 1 – 8 to 61 N·m (45 ft. lbs.) ENGINE 3.3/3.8L RS 9 - 103 CYLINDER HEAD (Continued) • • • (Do Step 2: Bolts 1 – 8 to 88 N·m (65 ft. lbs.) Step 3: Bolts 1 – 8 (again) to 88 N·m (65 ft. lbs.) Step 4: Bolts 1 – 8 turn an additional 1/4 Turn. not use a torque wrench for this step.) AND TESTING) for determining the source of a leak. NOTE: Bolt torque after 1/4 turn should be over 122 N·m (90 ft. lbs.). If not, replace the bolt. Fig. 22 CYLINDER HEAD TIGHTENING SEQUENCE (6) Inspect push rods and replace worn or bent rods. (7) Install the push rods. (8) Install the rocker arm and shaft assemblies. (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS - INSTALLATION) (9) Install the cylinder head covers. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) (10) Install the exhaust manifolds. (Refer to 9 ENGINE/MANIFOLDS/EXHAUST MANIFOLD INSTALLATION) (11) Install new O-ring on dipstick tube. Install dipstick tube assembly (Fig. 18). (12) Install the spark plugs. (13) Install upper and lower intake manifolds. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION) (14) Fill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (15) Connect negative cable to battery. Fig. 23 Cylinder Head Cover 1 - CYLINDER HEAD COVER 2 - BOLT CYLINDER HEAD COVER RIGHT REMOVAL CYLINDER HEAD COVER(S) (1) Disconnect negative cable from battery. (2) Remove the wiper module. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL) (3) Disconnect spark plug wires from plugs. (4) Disconnect power steering pump supply hose support clip from cylinder head cover (Fig. 24). (5) Disconnect PCV hose from cylinder head cover (Fig. 25). (6) Remove cylinder head cover bolts. (7) Remove cylinder head cover and gasket (Fig. 23). DESCRIPTION INSTALLATION The cylinder head covers are made of stamped steel. The covers are sealed with steel reinforced silicon rubber gaskets. The cylinder head cover uses rubber isolators at each fastener location (Fig. 23). (1) Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary. (2) Inspect seal on the cover bolt for wear or damage (Fig. 26). Replace bolt assembly as necessary. NOTE: Due to the tight packaging near the cylinder head covers, which makes spill clean-up difficult, a spill during an engine oil change may be misinterpreted as an oil leak. When investigating an oil leak in the location of the cylinder head covers and intake manifold, follow the procedure found in Oil Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSIS NOTE: The cylinder head cover bolts contain a torque limiter sleeve and a seal (Fig. 26). The seal and torque sleeve is replaced with the bolt. 9 - 104 ENGINE 3.3/3.8L RS CYLINDER HEAD COVER - RIGHT (Continued) Fig. 26 CYLINDER HEAD COVER GASKET Fig. 24 P/S Supply Hose 1 2 3 4 5 - POWER STEERING RESERVOIR CLAMP SUPPLY HOSE CLIP POWER STEERING PUMP 1 2 3 4 - CYLINDER HEAD COVER BOLT SEAL (SERVICED WITH BOLT) GASKET (5) Tighten cylinder head cover bolts to 12 N·m (105 in. lbs.) (Fig. 27). Fig. 27 Cylinder Head Cover 1 - CYLINDER HEAD COVER 2 - BOLT Fig. 25 PCV Hose 1 - HOSE - PCV 2 - PCV VALVE (3) Assemble gasket to cylinder cover by inserting the bolt assemblies through each bolt hole on the cover and gasket (Fig. 26). (4) Install cylinder head cover and bolts (Fig. 27). (6) Connect PCV hose to cylinder head cover. (7) Connect power steering pump supply hose support clip to cylinder head cover (Fig. 24). (8) Connect spark plug wires to spark plugs. (9) Install wiper module. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION) (10) Connect negative cable to battery. ENGINE 3.3/3.8L RS 9 - 105 CYLINDER HEAD COVER LEFT REMOVAL (1) (2) head (3) (4) Disconnect spark plug wires from spark plugs. Disconnect crankcase vent hose from cylinder cover. Remove cylinder head cover bolts. Remove cylinder head cover and gasket. Fig. 28 Valve Face and Seat INSTALLATION (1) Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary. (2) Assemble gasket to cylinder cover by inserting the fasteners through each bolt hole on cover and gasket (Fig. 26). (3) Install the cylinder head cover and bolts (Fig. 27). (4) Tighten cylinder head cover bolts to 12 N·m (105 in. lbs.) (Fig. 27). (5) Connect crankcase vent hose. (6) Connect spark plug wires to spark plugs. 1 2 3 4 - SEAT WIDTH FACE ANGLE SEAT ANGLE SEAT CONTACT AREA INTAKE/EXHAUST VALVES & SEATS DESCRIPTION The valves have chrome plated valve stems with four-bead lock grooves. The valve stem seals are made of Viton rubber. Fig. 29 Valve Margin 1 - VALVE FACE 2 - VALVE MARGIN OPERATION The two valves per cylinder are opened using hydraulic lifters, push rods, and rocker arms. STANDARD PROCEDURE - REFACING VALVES AND VALVE SEATS The intake and exhaust valves and seats are machined to specific angles (Fig. 28). VALVES (1) Inspect the remaining margin after the valves are refaced (Fig. 29). (Refer to 9 - ENGINE - SPECIFICATIONS) VALVE SEATS CAUTION: Remove metal from valve seat only. Do not remove material from cylinder head (Fig. 30). (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. Fig. 30 Refacing Valve Seats 1 2 3 4 - REFACING STONE MUST NOT CUT INTO CYLINDER HEAD STONE PILOT SEAT 9 - 106 ENGINE 3.3/3.8L RS INTAKE/EXHAUST VALVES & SEATS (Continued) (2) Measure the concentricity of valve seat using dial indicator (Fig. 31). Total runout should not exceed 0.051 mm (0.002 in.) total indicator reading. 0.794 mm (0.0312 in.) spacer in head counterbore to bring spring height back within specifications. Fig. 31 Measurement of Valve Seat Runout Fig. 32 Checking Valve and Spring Installed Height 1 - DIAL INDICATOR (3) Inspect the valve seat using Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLYwith Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise cylinder head must be replaced. (4) When seat is properly positioned the width of intake and exhaust seats should be 1.50–2.00 mm (0.059–0.078 in.) (Fig. 28). (5) After grinding the valve seats or faces, install the valve in cylinder head and check valve installed height by measuring from valve tip to spring seat (Fig. 32). Remove valve from cylinder head and grind valve tip until within specifications. Check valve tip for scoring. The tip chamfer should be reground (if necessary) to prevent seal damage when the valve is installed. (6) Check the valve spring installed height after refacing the valve and seat (Fig. 32).If valves and/or seats are reground, measure the installed height of springs (Fig. 32), make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than specifications, install a 1 2 3 4 - SPRING RETAINER VALVE INSTALLED HEIGHT* - 48.1–49.7 mm (1.89–1.95 in.) CYINDER HEAD SURFACE SPRING INSTALLED HEIGHT* - 41.1–42.7 mm (1.61–1.68 in.) *(MEASURED FROM TOP OF SPRING SEAT) REMOVAL (1) With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-D with adapter 8464 (Refer to 9 - ENGINE SPECIAL TOOLS). (2) Remove valve retaining locks. (3) Slowly release valve spring compressor. Remove valve spring retainer, valve spring, and valve stem seal. (4) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. CLEANING (1) Clean all valves thoroughly burned, warped and cracked valves. and discard INSPECTION VALVES (1) Clean and inspect valves thoroughly. Replace burned, warped and cracked valves. (2) Measure valve stems for wear (Fig. 33). For valve specifications, (Refer to 9 - ENGINE - SPECIFICATIONS). NOTE: Valve stems are chrome plated and should not be polished (Fig. 33). ENGINE 3.3/3.8L RS 9 - 107 INTAKE/EXHAUST VALVES & SEATS (Continued) INSTALLATION (1) Coat valve stems with clean engine oil and insert them in cylinder head. (2) Install valve spring seat on head (Fig. 36). (3) Install new seals on all valve stems and over valve guides (Fig. 36). Install valve springs and valve retainers (Fig. 36). (4) Install the valve springs. (Refer to 9 ENGINE/CYLINDER HEAD/VALVE SPRINGS INSTALLATION) VALVE SPRINGS Fig. 33 Intake and Exhaust Valves 1 2 3 4 - MARGIN FACE STEM VALVE SPRING RETAINER LOCK GROOVES VALVE GUIDES DESCRIPTION The valve springs are a bee-hive shaped design (Fig. 35). The springs are seated on a steel washer on the cylinder head with retainers and locks retaining the springs (Fig. 36). The springs are installed with the smaller diameter against spring retainer (Fig. 35). (1) Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. (2) Measure valve stem-to-guide clearance as follows: (3) Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat. A small piece of hose may be used to hold valve in place. (4) Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 34). (5) Move valve to and from the indicator. For clerance specifications, (Refer to 9 - ENGINE - SPECIFICATIONS). NOTE: Replace cylinder head if stem-to-guide clearance exceeds specifications, or if guide is loose in cylinder head. Fig. 35 Valve Spring 1 - VALVE SPRING (TOP - SMALLER DIAMETER) OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber. Fig. 34 Measuring Valve Guide Wear - Typical 9 - 108 ENGINE 3.3/3.8L RS VALVE SPRINGS (Continued) Fig. 36 VALVE COMPONENTS 1 2 3 4 - VALVE LOCKS RETAINERS VALVE SPRINGS VALVE STEM SEALS REMOVAL REMOVAL - CYLINDER HEAD OFF (1) With the cylinder head on a bench, position Special Tool C-3422-D with 8464 Adapter on the valve and spring retainer (Fig. 37). (2) Compress the spring only enough to remove the valve retainer locks. (3) Slowly release the spring tension and remove the valve spring and retainer. (4) For removal of the valve stem seal (Refer to 9 ENGINE/CYLINDER HEAD/VALVE STEM SEALS REMOVAL). REMOVAL - CYLINDER HEAD ON (1) Disconnect negative cable from battery. (2) Remove spark plug wires and all spark plugs. (3) Remove cylinder head cover(s). (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) 5 6 7 8 - SPRING SEATS CYLINDER HEAD VALVE - EXHAUST VALVE - INTAKE (4) Remove rocker arms and shaft. (Refer to 9 ENGINE/CYLINDER HEAD/ROCKER ARMS REMOVAL) (5) Rotate engine until the piston in the cylinder bore requiring spring removal is at TDC. (6) Install Special Tool 8453 to the cylinder head (Fig. 38). Tighten the attaching bolts to 23 N·m (200 in. lbs.). (7) Install a spark plug adapter in the spark plug hole. Connect air hose that can supply 620.5–689 kPa (90–100 psi) of air pressure to adapter. This is to hold valves in place while servicing components. (8) Locate the forcing screw and spring retainer adapter assembly over the spring requiring removal (Fig. 38). (9) Slowly turn the forcing screw clockwise (compressing the valve spring) until the valve keepers can be removed. (10) Turn forcing screw counterclockwise to relieve spring tension. Remove retainer and valve spring. ENGINE 3.3/3.8L RS 9 - 109 VALVE SPRINGS (Continued) spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to Engine Specifications to obtain specified height and allowable tensions (Refer to 9 ENGINE - SPECIFICATIONS). Replace any springs that do not meet specifications. Fig. 37 VALVE SPRING - REMOVE/INSTALL 1 - SPECIAL TOOL C-3422-D SPRING COMPRESSOR 2 - SPECIAL TOOL 8464 ADAPTER (11) Repeat procedure for each cylinder requiring valve spring removal. Fig. 39 TESTING VALVE SPRING 1 - SPECIAL TOOL C-647 INSTALLATION INSTALLATION - CYLINDER HEAD OFF Fig. 38 VALVE SPRING - REMOVE/INSTALL (HEAD ON) 1 - SPECIAL TOOL 8453 2 - BOLTS - SPECIAL TOOL ATTACHING 3 - AIR SUPPLY HOSE ADAPTER INSPECTION Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 39). As an example; the compression length of a spring to be tested is 38.00 mm (1.496 in.). Turn the table of Tool C-647 until surface is in line with the 38.00 mm (1.496 in.) mark on the threaded stud and the zero mark on the front. Place (1) If removed, install a new valve stem seal (Refer to 9 - ENGINE/CYLINDER HEAD/VALVE STEM SEALS - INSTALLATION). (2) Position valve spring and retainer on spring seat. (3) Using Special Tool C-3422-D with 8464 Adapter (Fig. 37), compress the spring only enough to install the valve retainer locks. Install valve retainer locks. (4) Slowly release the spring tension. Ensure the retainer locks are seated properly. INSTALLATION - CYLINDER HEAD ON (1) The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not pinch seal between retainer and top of valve guide. 9 - 110 ENGINE 3.3/3.8L RS VALVE SPRINGS (Continued) (2) Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at TDC on the valve spring that is being covered. (3) Remove spark plug adapter tool. (4) Install rocker arms and shaft assembly. (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS INSTALLATION) (5) Install cylinder head covers. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) (6) Install spark plugs and connect wires. (7) Connect negative cable to battery. ROCKER ARMS REMOVAL - ROCKER ARMS AND SHAFT (1) Remove the cylinder head cover(s). (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) NOTE: Rocker arm shaft bolts are captured to the shaft. (2) Loosen the rocker shaft bolts (Fig. 40), rotating one turn each, until all valve spring pressure is relieved. (3) Remove the rocker arms and shaft assembly (Fig. 40). (4) For rocker arm disassembly procedures, (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS DISASSEMBLY). DESCRIPTION DESCRIPTION - ROCKER ARMS The rocker arms are installed on the rocker arm shaft. The rocker arms and shaft assembly is attached to the cylinder head with seven bolts and retainers. The rocker arms are made of stamped steel. DESCRIPTION - PUSHRODS The pushrods are made of steel and are a hollow design. The pushrods are positioned between the hydraulic lifter and the rocker arm. Fig. 40 ROCKER ARMS AND SHAFT 1 - ROCKER ARMS AND SHAFT ASSEMBLY 2 - ROCKER SHAFT BOLTS OPERATION OPERATION - ROCKER ARMS The rocker arm pivots on the rocker shaft. Rocker arms are used to translate up and down motions provided by the camshaft, hydraulic lifter, and pushrod on one end, into a down and up motions on the valve stem on the opposing end. OPERATION - PUSHRODS The pushrod is a solid link between the hydraulic lifter and the rocker arm. Also, the pushrod supplies engine oil from the hydraulic lifter to the rocker arm. DISASSEMBLY - ROCKER ARMS AND SHAFT CAUTION: Do not attempt to drive the bolt from the rocker shaft. This can damage the retainer and bolt assembly. (1) Remove the rocker arm retainer and bolt by performing the following procedure: (a) Using adjustable pliers, grip the edges of the retainer (Fig. 41). (b) Apply an upward force with a slight rocking motion until the retainer disengages from shaft (Fig. 41). (2) Remove rocker arms (Fig. 42). Identify the component locations for reassembly in original locations. ENGINE 3.3/3.8L RS 9 - 111 ROCKER ARMS (Continued) Fig. 41 ROCKER ARM RETAINER - REMOVAL 1 - ADJUSTABLE PLIERS 2 - ROCKER SHAFT BOLT ASSEMBLY - ROCKER ARMS AND SHAFT (1) Install rocker arms on the shaft (Fig. 42). Install in the orginal positions if re-used. Ensure the rocker shaft, all the retainers and washers are properly positioned and installed in the correct locations (Fig. 42). (2) Install rocker arms and shaft to the cylinder head. (Refer to 9 - ENGINE/CYLINDER HEAD/ ROCKER ARMS - INSTALLATION) INSTALLATION - ROCKER ARMS AND SHAFT CAUTION: Ensure the longer shaft retaining bolt is installed in the proper location on the rocker shaft. (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS - ASSEMBLY) 3 - ROCKER ARM RETAINER (1) Position the rocker arm and shaft assemblies on the pedestal mounts. CAUTION: Ensure all pushrods are properly located on the lifter and the rocker arm socket. (2) Align each rocker arm socket with each pushrod end. CAUTION: The rocker arm shaft should be tightened down slowly, starting with the center bolts. Allow 20 minutes lifter bleed down time after installation of the rocker shafts before engine operation. (3) Slowly tighten rocker shaft bolts evenly until shaft is seated. Tighten bolts to 23 N·m (200 in. lbs.) (Fig. 43). (4) Install the cylinder head cover(s). (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) 9 - 112 ENGINE 3.3/3.8L RS ROCKER ARMS (Continued) Fig. 42 ROCKER ARMS AND SHAFT 1 2 3 4 - BOLT (ROCKER SHAFT OIL FEED - LONGER LENGTH) - SHAFT RETAINER/SPACER - 21.5 mm (0.84 in.) -SHAFT RETAINER/SPACER - 37.5 mm (1.47 in.) - SHAFT RETAINER/SPACER - 40.9 mm (1.61 in.) 5 - ROCKER ARM - EXHAUST 6 - WASHER 7 - ROCKER ARM - INTAKE (LARGER OFFSET) 8 - ROCKER ARMS LUBRICATION FEED HOLE (POSITION UPWARD & TOWARD VALVE SPRING) VALVE STEM SEALS DESCRIPTION The valve stem seals are made of Viton rubber. The seals are positioned over the valve stem and seated on the valve guide (Fig. 44). Fig. 43 ROCKER ARMS AND SHAFT 1 - ROCKER ARMS AND SHAFT ASSEMBLY 2 - ROCKER SHAFT BOLTS Fig. 44 Valve Stem Seal ENGINE 3.3/3.8L RS 9 - 113 VALVE STEM SEALS (Continued) REMOVAL (1) Remove the valve springs. (Refer to 9 ENGINE/CYLINDER HEAD/VALVE SPRINGS REMOVAL) (2) Remove the valve stem seal (Fig. 44). INSTALLATION (1) Install valve guide, 44). Do not guide. (2) Install CYLINDER TION) the valve stem seal squarely over the using the valve stem as a guide (Fig. force the seal against top of the valve the valve spring. (Refer to 9 - ENGINE/ HEAD/VALVE SPRINGS - INSTALLA- ENGINE BLOCK DESCRIPTION The cylinder block is made of cast iron and is a deep skirt design. STANDARD PROCEDURE - CYLINDER BORE HONING (1) Used carefully, the cylinder bore resizing hone, recommended tool C-823 or equivalent, equipped with 220 grit stones, is the best tool for this honing procedure. In addition to deglazing, it will reduce taper and out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes will clean up a bore and maintain the required limits. (2) Deglazing of the cylinder walls may be done using a cylinder surfacing hone, recommended tool C-3501 or equivalent, equipped with 280 grit stones, if the cylinder bore is straight and round. 20–60 strokes depending on the bore condition, will be sufficient to provide a satisfactory surface. Use a light honing oil. Do not use engine or transmission oil, mineral spirits or kerosene. Inspect cylinder walls after each 20 strokes. (3) Honing should be done by moving the hone up and down fast enough to get a cross-hatch pattern. When hone marks intersect at 40-60 degrees, the cross hatch angle is most satisfactory for proper seating of rings (Fig. 45). (4) A controlled hone motor speed between 200–300 RPM is necessary to obtain the proper crosshatch angle. The number of up and down strokes per minute can be regulated to get the desired 40–60 degree angle. Faster up and down strokes increase the cross-hatch angle. (5) After honing, it is necessary that the block be cleaned again to remove all traces of abrasive. Fig. 45 Cylinder Bore Cross-Hatch Pattern 1 - CROSS-HATCH PATTERN 2 - 40°–60° CAUTION: Ensure all abrasives are removed from engine parts after honing. It is recommended that a solution of soap and hot water be used with a brush and the parts then thoroughly dried. The bore can be considered clean when it can be wiped clean with a white cloth and cloth remains clean. Oil the bores after cleaning to prevent rusting. CLEANING Clean cylinder block thoroughly using a suitable cleaning solvent. INSPECTION ENGINE BLOCK (1) Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. (2) If new core plugs are to be installed, (Refer to 9 - ENGINE - STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS). (3) Examine block and cylinder bores for cracks or fractures. (4) Check block deck surfaces for flatness. Deck surface must be within service limit of 0.1 mm (0.004 in.). CYLINDER BORE NOTE: The cylinder bores should be measured at normal room temperature, 21°C (70°F). 9 - 114 ENGINE 3.3/3.8L RS ENGINE BLOCK (Continued) The cylinder walls should be checked for out-ofround and taper with Tool C119 or equivalent (Fig. 46) (Refer to 9 - ENGINE - SPECIFICATIONS). If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted. Fig. 47 CAMSHAFT AND BEARINGS 1 2 3 4 - CAMSHAFT THRUST PLATE BOLT CAMSHAFT BEARINGS (SERVICED WITH BLOCK) 1 2 3 4 - CAMSHAFT - 3.3L ENGINE CAST-IN RING CAMSHAFT - 3.8L ENGINE MACHINED CAST-IN RING Fig. 46 Checking Cylinder Bore Size Measure the cylinder bore at three levels in directions A and B (Fig. 46). Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. (Refer to 9 - ENGINE - SPECIFICATIONS). CAMSHAFT & BEARINGS (IN BLOCK) DESCRIPTION The nodular iron camshaft is mounted in the engine block and supported with four steel backed aluminum bearings (Fig. 47). A thrust plate, located in front of the first bearing, is bolted to the block and controls the camshaft end play (Fig. 47). To distinguish camshafts between the 3.3L and 3.8L engines, a cast-in ring is located between the rear bearing journal and rear lobe (Fig. 48). The 3.3L engine application is as-cast only. The 3.8L engine application the cast ring is machined off. OPERATION The camshaft is driven by the crankshaft through a timing chain and sprockets. The camshaft has pre- Fig. 48 CAMSHAFT IDENTIFICATION cisely machined (egg-shaped) lobes to provide accurate valve timing and duration. REMOVAL (1) Remove the engine assembly from vehicle. (Refer to 9 - ENGINE - REMOVAL) Remove the cylinder heads. (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL) (2) Remove the timing chain and camshaft sprocket. (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT/CHAIN AND SPROCKETS REMOVAL) (3) Remove the hydraulic lifters. (Refer to 9 ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS (CAM IN BLOCK) - REMOVAL). Identify each tappet for reinstallation in original location. ENGINE 3.3/3.8L RS 9 - 115 CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (4) Remove camshaft thrust plate (Fig. 47). (5) Install a long bolt into front of camshaft to facilitate removal of the camshaft. (6) Remove the camshaft (Fig. 47), being careful not to damage cam bearings with the cam lobes. NOTE: The camshaft bearings are serviced with the engine block. INSPECTION (1) Check the cam lobes and bearing surfaces for abnormal wear and damage (Fig. 49). Replace camshaft as required. NOTE: If camshaft is replaced due to lobe wear or damage, always replace the lifters. (2) Measure the lobe actual wear (unworn area wear zone = actual wear) (Fig. 49) and replace camshaft if out of limit. Standard value is 0.0254 mm (0.001 in.), wear limit is 0.254 mm (0.010 in.). (6) Install the timing chain and sprockets. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/ CHAIN AND SPROCKETS - INSTALLATION) NOTE: When camshaft is replaced, all of the hydraulic lifters must be replaced also. (7) Install the hydraulic lifters (Refer to 9 ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS (CAM IN BLOCK) - INSTALLATION). Each lifter reused must be installed in the same position from which it was removed. (8) Install the timing chain cover. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (9) Install the cylinder heads. (Refer to 9 ENGINE/CYLINDER HEAD - INSTALLATION) (10) Install the cylinder head covers. (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) (11) Install the lower and upper intake manifolds. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION) (12) Install the engine assembly. (Refer to 9 ENGINE - INSTALLATION) CONNECTING ROD BEARINGS STANDARD PROCEDURE - MEASURING CONNECTING ROD BEARING CLEARANCE Fig. 49 Checking Camshaft for Wear (Typical) 1 2 3 4 5 - UNWORN AREA - ACTUAL WEAR - BEARING JOURNAL - LOBE - WEAR ZONE INSTALLATION (1) Lubricate camshaft lobes and camshaft bearing journals with engine oil. (2) Install a long bolt into the camshaft to assist in the installation of the camshaft. (3) Carefully install the camshaft in engine block. (4) Install camshaft thrust plate and bolts (Fig. 47). Tighten to 12 N·m (105 in. lbs.) torque. (5) Measure camshaft end play. (Refer to 9 ENGINE - SPECIFICATIONS) If not within specifications, replace thrust plate. The bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. Fit all rods on one bank until complete. Connecting rod bearings are available in the standard size and the following undersizes: 0.025 mm (0.001 in.) and 0.250 mm (0.010 in.). CAUTION: Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps. Measure connecting rod journal for taper and outof-round. (Refer to 9 - ENGINE/ENGINE BLOCK/ CRANKSHAFT - INSPECTION) The connecting rod bearing clearances can be determined by use of Plastigage or the equivalent. The following is the recommended procedure for the use of Plastigage: (1) Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. (2) Remove oil film from surface to be checked. Plastigage is soluble in oil. 9 - 116 ENGINE 3.3/3.8L RS CONNECTING ROD BEARINGS (Continued) (3) Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 in.) off center and away from the oil hole. In addition, suspect areas can be checked by placing Plastigage in that area. (4) Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. (5) Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package (Fig. 50). Locate the band closest to the same width. This band indicates the amount of oil clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Engine Specifications (Refer to 9 - ENGINE - SPECIFICATIONS). Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds wear limit specification, replace the bearing. CRANKSHAFT DESCRIPTION DESCRIPTION - 3.3L The nodular iron crankshaft is supported by four main bearings, with number two position the thrust bearing (Fig. 51). Crankshaft end sealing is provided by front and rear rubber seals. Fig. 51 CRANKSHAFT AND ENGINE BLOCK - 3.3L Fig. 50 Measuring Connecting Rod Bearing Clearance 1 - MAIN BEARING CAP No. 4 2 - MAIN BEARING CAP No. 3 3 - MAIN BEARING CAP No. 2 4 - MAIN BEARING CAP BOLT (QTY. 2 PER CAP) 5 - MAIN BEARING CAP No. 1 6 - LOWER MAIN BEARING - THRUST 7 - UPPER MAIN BEARING - THRUST 8 - ENGINE BLOCK 9 - UPPER MAIN BEARINGS 10 - CRANKSHAFT 11 - LOWER MAIN BEARINGS ENGINE 3.3/3.8L RS 9 - 117 CRANKSHAFT (Continued) DESCRIPTION - 3.8L The nodular iron crankshaft is supported by four main bearings, with number two position providing thrust bearing location (Fig. 52). Each main bearing cap has two vertical retaining bolts. The two center main caps have horizontal bolts to add increased rigidity to the lower engine block (Fig. 52). Crankshaft end sealing is provided by front and rear rubber seals. STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY (1) Mount a dial indicator to front of engine with the locating probe on nose of crankshaft (Fig. 53). (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. (Refer to 9 - ENGINE SPECIFICATIONS) for end play specification. Fig. 53 Checking Crankshaft End Play—Typical REMOVAL Fig. 52 CRANKSHAFT AND BLOCK - 3.8L 1 - MAIN BEARING CAP No. 4 2 - MAIN BEARING CAP No. 3 3 - MAIN BEARING CAP No. 2 4 - MAIN BEARING CAP BOLT 5 - MAIN BEARING CAP No. 1 6 - THRUST MAIN BEARING - LOWER 7 - THRUST MAIN BEARING - UPPER 8 - MAIN BEARING CAP CROSS BOLT 9 - ENGINE BLOCK 10 - MAIN BEARING - UPPER 11 - CRANKSHAFT 12 - MAIN BEARING - LOWER OPERATION The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate. (1) Remove the engine assembly. (Refer to 9 ENGINE - REMOVAL) (2) Separate transaxle from engine. (3) Mount engine on an engine stand. (4) Remove the oil filter. (5) Remove the oil pan and oil pick-up tube. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN REMOVAL) (6) Remove the timing chain cover. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (7) Remove timing chain and sprockets. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (8) Remove crankshaft rear oil seal and retainer. (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL) (9) Rotate the crankshaft until connecting rod cap is accessible. (10) Mark connecting rod cap position using a suitable marker/scribe tool. (11) Remove connecting rod bearing cap. Use care to prevent damage to the crankshaft bearing surfaces. (12) Repeat removal procedure for each connecting rod cap. 9 - 118 ENGINE 3.3/3.8L RS CRANKSHAFT (Continued) (13) Remove and discard the main bearing cross bolts and washers (3.8L engine only). NOTE: Install new cross bolt and washer assembly (3.8L engine only) upon reassembly. (14) Remove the main bearing cap bolts (15) Remove the main bearing caps. (16) Remove the crankshaft from engine block. INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 54). Limits of taper or out of round on any crankshaft journals should within specitifications. (Refer to 9 - ENGINE SPECIFICATIONS) Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter. DO NOT grind thrust faces of No. 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. INSTALLATION (1) Lubricate with engine oil and install the crankshaft main bearing halves in the engine block. (2) Position the crankshaft in engine block (Fig. 56). (3) Perform main bearing fitting procedure. (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN BEARINGS - STANDARD PROCEDURE) (4) Inspect main cap bolts for stretching (Fig. 55). Replace bolts that are stretched. NOTE: The main cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced (Fig. 55). CAUTION: With the nodular cast iron crankshafts, it is important that the final paper or cloth polish be in the same direction as normal rotation in the engine. Fig. 55 Check for Stretched (Necked) Bolts 1 2 3 4 - STRETCHED BOLT THREADS ARE NOT STRAIGHT ON LINE THREADS ARE STRAIGHT ON LINE UNSTRETCHED BOLT (5) Install the main bearing caps and bolts. Tighten bolts to 41 N·m (30 ft. lbs.) plus 1⁄4 turn. NOTE: Install new cross bolt and washer assembly (3.8L engine only) upon reassembly. Fig. 54 Crankshaft Journal Measurements (6) Install and tighten the NEW cross bolts and washer assemblies (3.8L engine only) to 61 N·m (45 ft. lbs.) (Fig. 57). (7) Position and install the connecting rod and bearing caps on the crankshaft. (Refer to 9 ENGINE/ENGINE BLOCK/CONNECTING ROD BEARINGS - STANDARD PROCEDURE) (8) Install the crankshaft rear oil seal. (Refer to 9 ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - INSTALLATION) (9) Install the crankshaft sprocket. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) (10) Install the timing chain and camshaft sprocket. (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT/CHAIN AND SPROCKETS INSTALLATION) ENGINE 3.3/3.8L RS 9 - 119 CRANKSHAFT (Continued) Fig. 56 CRANKSHAFT AND BLOCK - 3.3L 1 - MAIN BEARING CAP No. 4 2 - MAIN BEARING CAP No. 3 3 - MAIN BEARING CAP No. 2 4 - MAIN BEARING CAP BOLT (QTY. 2 PER CAP) 5 - MAIN BEARING CAP No. 1 6 - LOWER MAIN BEARING - THRUST 7 - UPPER MAIN BEARING - THRUST 8 - ENGINE BLOCK 9 - UPPER MAIN BEARINGS 10 - CRANKSHAFT 11 - LOWER MAIN BEARINGS (11) Install the timing chain cover. (12) Install the oil pick-up tube and oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION) (13) Install the transaxle to the engine. (14) Install the engine assembly. (Refer to 9 ENGINE - INSTALLATION) Fig. 57 CRANKSHAFT AND BLOCK - 3.8L 1 - MAIN BEARING CAP No. 4 2 - MAIN BEARING CAP No. 3 3 - MAIN BEARING CAP No. 2 4 - MAIN BEARING CAP BOLT 5 - MAIN BEARING CAP No. 1 6 - THRUST MAIN BEARING - LOWER 7 - THRUST MAIN BEARING - UPPER 8 - MAIN BEARING CAP CROSS BOLT 9 - ENGINE BLOCK 10 - MAIN BEARING - UPPER 11 - CRANKSHAFT 12 - MAIN BEARING - LOWER CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE - MAIN BEARING FITTING Bearing caps are not interchangeable and should be marked at removal to insure correct assembly (Fig. 58). Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 3 and 4 are interchangeable. Upper main bearing halves of 1, 3 and 4 are interchangeable. 9 - 120 ENGINE 3.3/3.8L RS CRANKSHAFT MAIN BEARINGS (Continued) lowing is the recommended procedures for the use of Plastigage with the engine in the vehicle or engine on a repair stand. PLASTIGAGE METHOD—ENGINE IN-VEHICLE NOTE: The total clearance of the main bearings can only be determined with the engine in the vehicle by removing the weight of the crankshaft. This can be accomplished by either of two following methods: Fig. 58 Main Bearing Cap Identification Upper and lower number 2 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 59). All bearing cap bolts removed during service procedures are to be cleaned and lubricated with engine oil before installation. Bearing shells are available in standard and the following undersizes: 0.025 mm (0.001 in.) and 0.254 mm (0.010 in). Never install an undersize bearing that will reduce clearance below specifications. (1) Preferred method: a. Shim the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254 mm (0.010 in.) shim (e. g. cardboard, matchbook cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14–20 N·m (10–15 ft. lbs.). • When checking #1 main bearing shim #2 main bearing. • When checking #2 main bearing shim #1 & #3 main bearing. • When checking #3 main bearing shim #2 & #4 main bearing. • When checking #4 main bearing shim #3 main bearing. NOTE: Remove all shims before reassembling engine. Fig. 59 Main Bearing Identification 1 2 3 4 - OIL GROOVES OIL HOLES UPPER BEARINGS LOWER BEARINGS CRANKSHAFT BEARING OIL CLEARANCE Inspect the crankshaft bearing journals. (Refer to 9 ENGINE/ENGINE BLOCK/CRANKSHAFT INSPECTION) Engine crankshaft bearing clearances can be determined by use of Plastigage or the equivalent. The fol- (2) Alternative Method: a. Support the weight of the crankshaft with a jack under the counterweight adjacent to the bearing being checked. (3) Remove oil film from surface to be checked. Plastigage is soluble in oil. (4) Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 in.) off center and away from the oil holes (Fig. 60). (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. (5) Remove the bearing cap and compare the width of the flattened Plastigage (Fig. 61) with the scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. (Refer to 9 ENGINE - SPECIFICATIONS) Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. ENGINE 3.3/3.8L RS 9 - 121 CRANKSHAFT MAIN BEARINGS (Continued) NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. REMOVAL - CRANKSHAFT MAIN BEARINGS (1) Remove the oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL) (2) Identify main bearing caps before removal. (3) Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059 (Fig. 62) into the oil hole of crankshaft. (4) Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. Fig. 60 Plastigage Placed in Lower 1 - PLASTIGAGE Fig. 62 Upper Main Bearing Removing/Installing With Special Tool C-3059 Fig. 61 Clearance Measurement PLASTIGAGE METHOD—ENGINE OUT-OF-VEHICLE (1) With engine in the inverted position (crankshaft up) and mounted on a repair stand, remove main journal cap. (2) Remove oil from journal and bearing shell. (3) Cut Plastigage to same length as width of the bearing and place it in parallel with the journal axis (Fig. 60). (4) Carefully install the main bearing cap and tighten the bolts to specified torque. CAUTION: Do not rotate crankshaft or the Plastigage will be smeared. (5) Carefully remove the bearing cap and measure the width of the Plastigage at the widest part using the scale on the Plastigage package (Fig. 61). Refer to Engine Specifications for proper clearances (Refer to 9 - ENGINE - SPECIFICATIONS). If the clearance exceeds the specified limits, replace the main bearing(s) with the appropriate size, and if necessary, have the crankshaft machined to next undersize. 1 2 3 4 - SPECIAL TOOL C-3059 BEARING SPECIAL TOOL C-3059 BEARING INSTALLATION - CRANKSHAFT MAIN BEARINGS NOTE: One main bearing should be selectively fitted while all other main bearing caps are properly tightened. (1) For main bearing fitting procedure, (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN BEARINGS - STANDARD PROCEDURE) (2) Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft (Fig. 62). (3) Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059. (4) Inspect main cap bolts for stretching (Fig. 63). Replace bolts that are stretched. 9 - 122 ENGINE 3.3/3.8L RS CRANKSHAFT MAIN BEARINGS (Continued) NOTE: The main cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced (Fig. 63). (3) Remove accessory drive belt. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL) (4) Remove crankshaft damper. (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL) (5) Position Special Tool 6341A on crankshaft nose. Carefully screw the tool into the seal until it engages firmly (Fig. 64). Be careful not to damage that crankshaft seal surface of cover (6) Remove oil seal by turning the forcing screw until the seal disengages from the cover (Fig. 65). Fig. 63 Check for Stretched (Necked) Bolts 1 2 3 4 - STRETCHED BOLT THREADS ARE NOT STRAIGHT ON LINE THREADS ARE STRAIGHT ON LINE UNSTRETCHED BOLT (5) Install each main cap and tighten bolts finger tight. (6) Tighten number 1, 3 and 4 main cap bolts to 41 N·m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). (7) Rotate the crankshaft until the number 6 piston is at TDC. (8) To ensure correct thrust bearing alignment the following procedure must be done: a. Move crankshaft all the way to the rear of its travel. b. Then, move crankshaft all the way to the front of its travel. c. Wedge an appropriate tool between the rear of the cylinder block and rear crankshaft counterweight. This will hold the crankshaft in it’s most forward position. d. Tighten the #2 Thrust Bearing cap bolts to 41 N·m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the holding tool. (9) Install oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION) (10) Fill engine crankcase with proper oil to correct level. Fig. 64 Engaging Tool into Seal 1 - SEAL 2 - SPECIAL TOOL 6341A Fig. 65 Crankshaft Front Seal Removal CRANKSHAFT OIL SEAL FRONT REMOVAL (1) Disconnect negative cable from battery. (2) Raise vehicle on hoist. Remove right wheel and inner splash shield. 1 - SEAL 2 - SPECIAL TOOL 6341A ENGINE 3.3/3.8L RS 9 - 123 CRANKSHAFT OIL SEAL - FRONT (Continued) INSTALLATION (1) Position Special Tool C-4992-2 Guide, on the crankshaft nose (Fig. 66). (2) Position new seal over the guide with the seal spring in the direction of the engine front cover (Fig. 66). (3) Install seal using Special Tool C-4992-1 until seal is flush with cover. (Fig. 66). CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface. Contact of the pry tool blade against crankshaft edge (chamfer) is permitted. Fig. 66 CRANKSHAFT FRONT SEAL INSTALLATION 1 2 3 4 - SPECIAL TOOL C-4992-1 SEAL SPECIAL TOOL C-4992-2 CRANKSHAFT (4) Install crankshaft damper. (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER INSTALLATION) (5) Install accessory drive belt. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) (6) Install inner splash shield and right front wheel. (7) Lower vehicle and connect negative cable to battery. CRANKSHAFT OIL SEAL REAR REMOVAL (1) Remove the transaxle. Refer to TRANSAXLE AND POWER TRANSFER UNIT for procedure. (2) Remove the flex plate. (Refer to 9 - ENGINE/ ENGINE BLOCK/FLEX PLATE - REMOVAL) (3) Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal. Angle the pry tool (Fig. 67) through the dust lip against metal case of the seal. Pry out seal. Fig. 67 Crankshaft Rear Oil Seal - Removal 1 2 3 4 5 6 7 8 9 - REAR CRANKSHAFT SEAL ENGINE BLOCK ENGINE BLOCK REAR CRANKSHAFT SEAL METAL CASE PRY IN THIS DIRECTION CRANKSHAFT SCREWDRIVER REAR CRANKSHAFT SEAL DUST LIP SCREWDRIVER INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. (1) Place Special Tool 6926-1 magnetic pilot tool on crankshaft (Fig. 68). (2) Place seal over Special Tool 6926-1 Pilot. Using Special Tool 6926-2 Installer with C-4171 Handle, drive seal into the retainer housing (Fig. 68). (3) Install the flex plate. (Refer to 9 - ENGINE/ ENGINE BLOCK/FLEX PLATE - INSTALLATION) (4) Install transaxle. Refer to TRANSAXLE AND POWER TRANSFER UNIT for procedure. 9 - 124 ENGINE 3.3/3.8L RS CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 69 CRANKSHAFT REAR OIL SEAL 1 2 3 4 - OIL SEAL BOLT RETAINER - OIL SEAL GASKET FLEX PLATE 1 2 3 4 5 - Fig. 68 Rear Crankshaft Oil Seal—Installation REMOVAL SPECIAL TOOLS: C-4171 HANDLE 6926–2 INSTALLER 6926–1 GUIDE SEAL (1) Remove the transaxle (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE REMOVAL). (2) Remove flex plate attaching bolts. (3) Remove the flex plate (Fig. 70). CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL (1) Remove crankshaft rear oil seal (Refer to 9 ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL). (2) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (3) Remove oil seal retainer screws (Fig. 69). (4) Remove oil seal retainer (Fig. 69). (5) Clean engine block and retainer of oil and gasket material. Make sure surfaces are clean and free of oil. INSTALLATION (1) Position new gasket and install retainer on block (Fig. 69). Tighten attaching screws to 12 N·m (105 in. lbs.). (2) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (3) Install oil seal (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR INSTALLATION). Fig. 70 FLEX PLATE 1 - FLEX PLATE 2 - BOLT (QTY. 8) 3 - BACKING PLATE INSTALLATION (1) Position flex plate with backing plate on the crankshaft (Fig. 70). (2) Apply Mopart Lock & Seal Adhesive to the flex plate bolts. ENGINE 3.3/3.8L RS 9 - 125 FLEX PLATE (Continued) (3) Install flex plate bolts (Fig. 70). Tighten bolts to 95 N·m (70 ft. lbs.). (4) Install the transaxle (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE - INSTALLATION). HYDRAULIC LIFTERS (CAM IN BLOCK) DESCRIPTION The hydraulic lifters are a roller type design and are positioned in the cylinder block. The lifters are aligned and retained by a yoke and a retainer (Fig. 71). Lifter alignment is maintained by machined flats on lifter body. Lifters are fitted in pairs into six aligning yokes. The aligning yokes are secured by a yoke retainer (Fig. 71). DIAGNOSIS AND TESTING - HYDRAULIC LIFTERS HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY STEP Before disassembling any part of the engine to correct lifter noise, check the engine oil pressure. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) Check engine oil level. The oil level in the pan should never be above the MAX mark on dipstick, or below the MIN mark. Either of these two conditions could cause noisy lifters. OIL LEVEL TOO HIGH If oil level is above the MAX mark on dipstick, it is possible for the connecting rods to dip into the oil while engine is running and create foaming. Foam in oil pan would be fed to the hydraulic lifters by the oil pump causing them to become soft and allow valves to seat noisily. OIL LEVEL TOO LOW Low oil level may allow pump to take in air which when fed to the lifters it causes them to become soft and allows valves to seat noisily. Any leaks on intake side of pump, through which air can be drawn, will create the same lifter noise. Check the lubrication system from the intake strainer to the oil pump cover, including the relief valve retainer cap. When lifter noise is due to aeration, it may be intermittent or constant, and usually more than one lifter will be noisy. When oil level and leaks have been corrected, the engine should be operated at fast idle to allow all of the air inside of the lifters to be bled out. VALVE TRAIN NOISE To determine source of valve train noise, operate engine at idle with cylinder head covers removed and listen for source of the noise. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy lifters. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. Fig. 71 Hydraulic Lifters 1 2 3 4 - YOKE RETAINER - BOLT - YOKE RETAINER - ALIGNING YOKE - HYDRAULIC LIFTER Valve lifter noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger which will necessitate replacing the lifter, or by the plunger partially sticking in the lifter body cylinder. A heavy click is caused either by a lifter check valve not seating, or by foreign particles becoming wedged between 9 - 126 ENGINE 3.3/3.8L RS HYDRAULIC LIFTERS (CAM IN BLOCK) (Continued) the plunger and the lifter body causing the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, lifter assembly should be removed for inspection. REMOVAL (1) Remove the cylinder head(s). (Refer to 9 ENGINE/CYLINDER HEAD - REMOVAL) (2) Remove the yoke retainer and aligning yokes (Fig. 73). (3) Remove the hydraulic lifters. If necessary use Special Tool C-4129, or equivalent to remove lifters from bores. If lifters are to be reused, identify each lifter to ensure installation in original location. INSTALLATION (1) Lubricate the lifters with engine oil. NOTE: Position the lifter in bore with the lubrication hole facing upward (Fig. 72). (2) Install the hydraulic lifters with the lubrication hole facing upward towards middle of block (Fig. 72). Install lifters in original positions, if reused. Fig. 73 Lifter Aligning Yoke and Retainer 1 2 3 4 - YOKE RETAINER - BOLT - YOKE RETAINER - ALIGNING YOKE - HYDRAULIC LIFTER hydraulic lifters have filled with oil and have become quiet. PISTON & CONNECTING ROD DESCRIPTION Fig. 72 LIFTER LUBRICATION HOLE (3) Install lifter aligning yokes (Fig. 73). (4) Install yoke retainer and torque screws to 12 N·m (105 in. lbs.) (Fig. 73). (5) Install the cylinder heads. (Refer to 9 ENGINE/CYLINDER HEAD - INSTALLATION) (6) Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all The pistons are made of cast aluminum alloy and are a strutless, short skirt design. The piston rings consist of two compression rings and a three piece oil ring. Piston pins connect the piston to the forged steel connecting rods. The piston pins are a press fit into the connecting rod. OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft. ENGINE 3.3/3.8L RS 9 - 127 PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURE STANDARD PROCEDURE - FITTING CONNECTING RODS The bearing caps are not interchangeable or reversible, and should be marked at removal to ensure correct reassembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. For connecting rod bearing fitting (Refer to 9 - ENGINE/ENGINE BLOCK/CONNECTING ROD BEARINGS STANDARD PROCEDURE). Fit all connecting rods on one bank until complete. NOTE: The connecting rod cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced (Fig. 74). Fig. 75 Checking Connecting Rod Side Clearance STANDARD PROCEDURE - FITTING PISTONS The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location shown in (Fig. 76). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in (Fig. 77). Refer to Engine Specifications (Refer to 9 - ENGINE - SPECIFICATIONS). Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Fig. 74 Check for Stretched (Necked) Bolts 1 2 3 4 - STRETCHED BOLT THREADS ARE NOT STRAIGHT ON LINE THREADS ARE STRAIGHT ON LINE UNSTRETCHED BOLT Fig. 76 Piston Measurement Locations (1) Before installing the nuts the threads should be oiled with engine oil. (2) Install nuts finger tight on each bolt then alternately torque each nut to assemble the cap properly. (3) Tighten the nuts to 54 N·m PLUS 1/4 turn (40 ft. lbs. PLUS 1/4 turn). (4) Using a feeler gauge, check connecting rod side clearance (Fig. 75). Refer to Engine Specifications (Refer to 9 - ENGINE - SPECIFICATIONS). 1 - 39.8 mm (1.56 in. ) 3.3L ENGINE 2 - 33.0 mm (1.29 in.) 3.8L ENGINE REMOVAL (1) Disconnect negative cable from battery. (2) Remove the cylinder heads. (Refer to 9 ENGINE/CYLINDER HEAD - REMOVAL) (3) Remove the oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL) (4) Remove the top ridge of cylinder bores with a reliable ridge reamer, if necessary, before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. 9 - 128 ENGINE 3.3/3.8L RS PISTON & CONNECTING ROD (Continued) Fig. 79 Connecting Rod Protectors 1 - COVER ROD BOLTS WITH A SUITABLE COVERING WHEN REMOVING OR INSTALLING PISTON ASSEMBLY Fig. 77 Checking Cylinder Bore Size (5) Inspect connecting rods and connecting rod caps for cylinder identification. Identify them, if necessary (Fig. 78). Fig. 80 Piston Ring End Gap Position Fig. 78 Identify Connecting Rod to Cylinder 1 - CYLINDER NUMBER (6) Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 79). (7) Remove each piston and connecting rod assembly out of the cylinder bore. NOTE: Be careful not to nick crankshaft journals. (8) After removal, install bearing cap on the mating rod. INSTALLATION (1) Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 80). 1 2 3 4 5 - SIDE RAIL UPPER NO. 1 RING GAP PISTON PIN SIDE RAIL LOWER NO. 2 RING GAP AND SPACER EXPANDER GAP (2) Before installing the ring compressor, ensure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 80). (3) Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor (Fig. 81). Be sure position of rings does not change during this operation. (4) Position upper bearing onto connecting rod. Lubricate bearing with oil. (5) Install connecting rod bolt protectors (rubber hose or equivalent) on the connecting rod bolts (Fig. 81). ENGINE 3.3/3.8L RS 9 - 129 PISTON & CONNECTING ROD (Continued) (6) The pistons are marked with a “F” located near the piston pin. Install piston with this mark positioned to front of engine on both cylinder banks. The connecting rod oil squirt hole faces the major thrust (right) side of the engine block (Fig. 82). (7) Rotate crankshaft until the connecting rod journal is located in the center of the cylinder bore. Insert connecting rod and piston into cylinder bore. Carefully guide connecting rod over the crankshaft journal (Fig. 81). (8) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. (9) Install lower bearing shell and connecting rod cap (Fig. 81). Install nuts on cleaned and oiled rod bolts and tighten to 54 N·m (40 ft. lbs.) PLUS 1⁄4 turn. (10) Repeat procedure for each piston and connecting rod installation. Fig. 81 PISTON AND CONNECTING ROD INSTALLATION 1 2 3 4 5 6 - RING - OIL CONTROL RING - NO. 2 COMPRESSION RING - NO. 1 COMPRESSION RING - SIDE RAIL UPPER & LOWER PISTON RING COMPRESSOR NUT - CONNECTING ROD 7 - CAP - CONNECTING ROD 8 - BEARING - CONNECTING ROD LOWER 9 - CRANKSHAFT JOURNAL PROTECTOR (RUBBER HOSE) 10 - BEARING - CONNECTING ROD UPPER 11 - PISTON AND CONNECTING ROD ASSEMBLY 12 - PISTON LOCATION MARK (F = FRONT) 9 - 130 ENGINE 3.3/3.8L RS PISTON & CONNECTING ROD (Continued) Fig. 82 Piston and Connecting Rod Positioning (Front View of Engine) 1 - MAJOR THRUST SIDE OF PISTON (11) Install the cylinder heads. (Refer to 9 ENGINE/CYLINDER HEAD - INSTALLATION) (12) Install the oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION) (13) Fill engine crankcase with proper oil to correct level. (14) Connect negative cable to battery. 2 - OIL SQUIRT HOLE PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING (1) Wipe cylinder bore clean. Insert the ring and push down with piston to ensure squareness in bore to approximately 12 mm (0.50 in.) from top of cylinder bore. Check ring gap with a feeler gauge (Fig. 83). For clearance specification (Refer to 9 - ENGINE - SPECIFICATIONS). (2) Check piston ring to groove side clearance (Fig. 84). For clearance specification (Refer to 9 - ENGINE - SPECIFICATIONS) ENGINE 3.3/3.8L RS 9 - 131 PISTON RINGS (Continued) CAUTION: Install piston rings in the following order: a. b. c. d. e. Oil ring expander. Upper oil ring side rail. Lower oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring. Fig. 83 Piston Ring Gap 1 - FEELER GAUGE Fig. 85 Piston Ring Installation 1 2 3 4 5 Fig. 84 Piston Ring Side Clearance - NO. 1 PISTON RING NO. 2 PISTON RING SIDE RAIL OIL RING SPACER EXPANDER (2) Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander (Fig. 86). (3) Install upper side rail first and then the lower side rail. 1 - FEELER GAUGE REMOVAL (1) Remove piston and connecting rod. (Refer to 9 ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - REMOVAL) (2) Remove No. 1 and No.2 piston rings from piston using a ring expander tool (Fig. 87). (3) Remove upper oil ring side rail (Fig. 86). (4) Remove lower oil ring side rail (Fig. 86). (5) Remove oil ring expander (Fig. 86). INSTALLATION (1) Install rings with manufacturers I.D. mark (if present) facing up, to the top of the piston (Fig. 85). Fig. 86 Oil Ring Side Rail 1 - SIDE RAIL END 9 - 132 ENGINE 3.3/3.8L RS PISTON RINGS (Continued) (4) Install No. 2 piston ring and then No. 1 piston ring (Fig. 87). VIBRATION DAMPER REMOVAL (1) Disconnect negative cable from battery. (2) Raise vehicle on hoist. (3) Remove the right front wheel and inner splash shield. (4) Remove the accessory drive belt. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL) (5) Remove vibration damper bolt. (6) Insert Special Tool 8450 into crankshaft nose (Fig. 89). (7) Position 3-jaw puller Special Tool 1026 on damper as shown in (Fig. 89). Turn puller forcing screw until damper releases from crankshaft. (8) Remove the crankshaft vibration damper. Fig. 87 Piston Ring Installation (5) Position piston ring end gaps as shown in (Fig. 88). (6) Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control. Fig. 89 Vibration Damper - Removal 1 - SPECIAL TOOL 8450 - INSERT 2 - SPECIAL TOOL 1026 - 3 JAW PULLER INSTALLATION Fig. 88 Piston Ring End Gap Position 1 2 3 4 - GAP OF LOWER SIDE RAIL NO. 1 RING GAP GAP OF UPPER SIDE RAIL NO. 2 RING GAP AND SPACER EXPANDER GAP (1) Install crankshaft vibration damper using the forcing screw, nut, and thrust bearing/washer from Special Tool 8452 (Fig. 90). NOTE: To minimize friction and prolong tool life, lubricate the threads on the forcing screw of Special Tool 8452. (2) Position vibration damper on crankshaft. (3) Screw Special Tool 8452 into crankshaft until the bolt seats. Turn the nut to install damper until it seats fully. (4) Remove Special Tool 8452. (5) Install vibration damper bolt. Torque bolt to 54 N·m (40 ft. lbs.). ENGINE 3.3/3.8L RS 9 - 133 VIBRATION DAMPER (Continued) Fig. 90 Vibration Damper - Installation 1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452 2 - VIBRATION DAMPER 3 - THRUST BEARING / WASHER Fig. 91 Engine Hydro-type Mount - Right Side 1 2 3 4 5 - BOLT BOLT FRAME RAIL RIGHT MOUNT - 2.4L ENGINE RIGHT MOUNT - 3.3/3.8L ENGINE (6) Install the accessory drive belt. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION) (7) Install inner splash shield and right front wheel. (8) Connect negative cable to battery. FRONT MOUNT ENGINE MOUNTING REMOVAL DESCRIPTION The engine mounting system consist of four mounts; right and a left side support the powertrain, and a front and a rear mount control powertrain torque. The right side mount is a hydro-type (Fig. 91), all others are of molded rubber material. (1) Support the engine and transmission assembly with a floor jack so it will not rotate. (2) Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket (Fig. 92). (3) Remove six screws from air dam to allow access to the front mount screws. (4) Remove the front engine mount screws and remove the insulator assembly (Fig. 92). (5) Remove the front mounting bracket, if necessary (Fig. 92). INSTALLATION (1) Install the front mounting bracket, if removed (Fig. 92). (2) Install the front engine mount through bolt from the insulator and front crossmember mounting bracket (Fig. 92). (3) Install the insulator assembly and mounting screws (Fig. 92). 9 - 134 ENGINE 3.3/3.8L RS FRONT MOUNT (Continued) Fig. 92 Engine Mounting - Front 1 2 3 4 - CROSSMEMBER BOLT - 68 N·m (50 ft. lbs.) BOLT - 102 N·m (75 ft. lbs.) BOLT - 68 N·m (50 ft. lbs.) LEFT MOUNT REMOVAL (1) Raise the vehicle on hoist. (2) Remove the left front wheel. (3) Remove the left mount through bolt access cover. (4) Support the transaxle with a suitable jack. (5) Remove the engine front mount through bolt to allow left mount removal clearance (Fig. 92). (6) Remove the left mount through frame rail bolt (Fig. 93). (7) Lower transaxle for access to horizontal bolts. (8) Remove the horizontal bolts from the mount to the transaxle (Fig. 94) or (Fig. 95). 5 6 7 8 - BOLT 54 N·m (40 ft. lbs.) NUT - 68 N·m (50 ft. lbs.) MOUNT - ENGINE FRONT BRACKET - ENGINE FRONT MOUNT NOTE: To remove mount, additional lowering of transaxle may be required. (9) Remove left mount. INSTALLATION (1) Install left mount on transaxle (Fig. 94) or (Fig. 95). (2) Raise transaxle with jack until left mount is in position. (3) Install left mount through bolt (Fig. 93). (4) Install left mount through bolt access cover. (5) Install front mount through bolt (Fig. 92). (6) Install left front wheel. (7) Lower vehicle. ENGINE 3.3/3.8L RS 9 - 135 LEFT MOUNT (Continued) Fig. 95 LEFT MOUNT - 41TE TRANSAXLE Fig. 93 LEFT MOUNT TO BRACKET 1 2 3 4 5 6 - BOLT - BRACKET TO FRAME RAIL 68 N·m (50 ft. lbs.) BOLT - MOUNT TO RAIL THRU 75 N·m (55 ft. lbs.) BOLT - LEFT MOUNT TO TRANSAXLE 54 N·m (40 ft. lbs.) TRANSAXLE MOUNT - LEFT BRACKET - LEFT MOUNT 1 - LEFT MOUNT ASSEMBLY 2 - BOLT - 54 N·m (40 ft. lbs.) 3 - TRANSAXLE - 41TE REAR MOUNT REMOVAL (1) Raise vehicle on hoist. (2) Remove the rear mount heat shield (Fig. 96). Fig. 94 LEFT MOUNT - 31TH TRANSAXLE 1 - LEFT MOUNT ASEMBLY 2 - BOLT - 54 N·m (40 ft. lbs.) 3 - TRANSAXLE - 31TH Fig. 96 REAR MOUNT HEAT SHIELD 1 2 3 4 - BOLT - HEAT SHIELD 11 N·m (100 in. lbs.) HEAT SHIELD CLIP REAR MOUNT (3) Remove the through bolt from the mount and rear mount bracket (Fig. 97). (4) Remove the mount bolts (Fig. 97). (5) Remove the rear mount (Fig. 97). (6) For rear mount bracket removal, remove the bolts attaching bracket to transaxle (Fig. 98). (7) Remove rear mount bracket. 9 - 136 ENGINE 3.3/3.8L RS REAR MOUNT (Continued) INSTALLATION (1) Install rear mount bracket, if removed (Fig. 98). (2) Install the rear mount and bolts (Fig. 97). Tighten bolts to 54 N·m (40 ft. lbs.). (3) Install the mount through bolt to the mount and bracket (Fig. 97). Tighten through bolt to 54 N·m (40 ft. lbs.). (4) Install the rear mount heat shield (Fig. 96). (5) Lower vehicle on hoist. Fig. 97 REAR MOUNT 1 2 3 4 - BOLT 54 N·m (40 ft. lbs.) REAR MOUNT BRACKET THRU-BOLT 54 N·m (40 ft. lbs.) REAR MOUNT Fig. 98 REAR MOUNT BRACKET - (all engines) 1 - BOLT - VERTICAL 102 N·m (75 ft. lbs.) 2 - BRACKET - REAR MOUNT 3 - BOLT - HORIZONTAL 102 N·m (75 ft. lbs.) ENGINE 3.3/3.8L RS RIGHT MOUNT REMOVAL (1) Remove air cleaner housing lid and clean air hose from throttle body. (2) Remove air cleaner element and housing. (3) Disconnect make-up air hose from cylinder head cover. (4) Remove the load on the right engine mount by carefully supporting the engine assembly with a floor jack. (5) Disconnect electrical harness support clips from engine mount bracket. (6) Remove the bolts attaching the engine mount to the frame rail (Fig. 99). (7) Remove the three bolts attaching the engine mount to the engine bracket (Fig. 99). (8) Remove the right engine mount (Fig. 99). 9 - 137 INSTALLATION (1) Install engine bracket (if removed). Tighten bolts to 33 N·m (24 ft. lbs.). (2) Position right engine mount and install frame rail to mount bolts (Fig. 99). Tighten bolts to 68 N·m (50 ft. lbs.). (3) Install the mount to engine bracket bolts and tighten to 54 N·m (40 ft. lbs.). (Fig. 99) (4) Connect electrical harness support clips to engine mount bracket. (5) Remove jack from under engine. (6) Connect make-up air hose to cylinder head cover. (7) Install air cleaner housing and element. (8) Install air cleaner housing lid and clean air tube to throttle body. LUBRICATION DESCRIPTION The lubrication system is a full flow filtration pressure feed type. The oil pump is mounted in the timing chain cover and is driven by the crankshaft OPERATION Oil from the oil pan is pumped by a internal gear type oil pump directly coupled to the crankshaft. The pressure is regulated by a relief valve located in the timing chain cover. The oil is pumped through an oil filter and feeds a main oil gallery. This oil gallery feeds oil under pressure to the main and rod bearings, camshaft bearings. Passages in the cylinder block feed oil to the hydraulic lifters and rocker shaft brackets which feeds the rocker arm pivots (Fig. 100). DIAGNOSIS AND TESTING - ENGINE OIL PRESSURE Fig. 99 Right Engine Mount 1 2 3 4 5 - RIGHT ENGINE MOUNT BOLT - MOUNT TO FRAME RAIL BOLT - MOUNT TO ENGINE ENGINE MOUNT BRACKET RIGHT FRAME RAIL (1) Disconnect and remove oil pressure switch (Refer to 9 - ENGINE/LUBRICATION/OIL PRESSURE SENSOR/SWITCH - REMOVAL). (2) Install Special Tools C-3292 Gauge with 8406 Adaptor. For Special Tool identification, (Refer to 9 ENGINE - SPECIAL TOOLS). (3) Start engine and record oil pressure. Refer to Oil Pressure in Engine Specifications for the correct pressure (Refer to 9 - ENGINE - SPECIFICATIONS). 9 - 138 ENGINE 3.3/3.8L RS LUBRICATION (Continued) Fig. 100 Engine Oiling System 1 - OIL SUPPLY FOR BALL SOCKET THROUGH PUSH ROD 2 - OIL SUPPLY PASSAGE FROM SHAFT TO ROCKER ARM 3 - ROCKER SHAFT 4 - OIL FLOWS TO ONLY ONE PEDASTAL ON EACH HEAD; THIRD FROM REAR ON RIGHT HEAD, THIRD FROM FRONT ON LEFT HEAD 5 - ROCKER SHAFT TOWER 6 - CRANKSHAFT OIL STANDARD PROCEDURE STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. (Refer to LUBRICATION & MAINTENANCE/MAINTENANCE SCHEDULES - DESCRIPTION) 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 GOVERN- 7 - OUTER ROTOR 8 - INNER ROTOR 9 - RELIEF VALVE 10 - OIL PAN 11 - OIL SCREEN 12 - OIL PUMP CASE MENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Run engine until achieving normal operating temperature. (1) Position the vehicle on a level surface and turn engine off. (2) Open hood, remove oil fill cap. (3) Hoist and support vehicle on safety stands. Refer to Hoisting and Jacking Recommendations. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE) (4) Place a suitable drain pan under crankcase drain (Fig. 101). (5) Remove drain plug from crankcase (Fig. 101) and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. (6) Remove oil filter. (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - REMOVAL) (7) Install and tighten drain plug in crankcase. (8) Install new oil filter. (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION) ENGINE 3.3/3.8L RS 9 - 139 OIL (Continued) (9) Lower vehicle and fill crankcase with specified type and amount of engine oil. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES DESCRIPTION) (10) Install oil fill cap. (11) Start engine and inspect for leaks. (12) Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. STANDARD PROCEDURE - ENGINE OIL LEVEL CHECK Fig. 101 Engine Oil Drain Plug and Oil Filter 1 - DRAIN PLUG 2 - OIL FILTER The best time to check engine oil level is after it has sat overnight, or if the engine has been running, 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 (Fig. 102). Add only when the level is at or below the ADD mark. Fig. 102 Engine Oil Level Dipstick and Fill Locations 1 - COOLANT RECOVERY CONTAINER 2 - ENGINE OIL FILL CAP 3 - ENGINE OIL LEVEL DIPSTICK 4 - RADIATOR PRESSURE CAP 9 - 140 ENGINE 3.3/3.8L RS OIL COOLER & LINES DESCRIPTION An engine oil cooler is used on 3.3/3.8L engines (Heavy Duty Cooling Only) (Fig. 104). The cooler is a coolant-to-oil type and mounted between the oil filter and engine block. OPERATION Engine oil travels from the oil filter and into the oil cooler. Engine oil then exits the cooler into the main gallery. Engine coolant flows into the cooler from the heater return tube and exits into the water pump inlet. REMOVAL (1) Drain cooling system (Refer to 7 - COOLING STANDARD PROCEDURE - COOLING SYSTEM DRAINING). (2) Disconnect oil cooler inlet and outlet hoses (Fig. 103). (3) Remove oil filter. (4) Remove oil cooler attachment fitting (Fig. 104). (5) Remove oil cooler. Fig. 104 Engine Oil Cooler - 3.3/3.8L (Heavy Duty Cooling) 1 2 3 4 5 - OIL FILTER ADAPTER CONNECTOR ENGINE OIL COOLER OIL COOLER ATTACHMENT FITTING OIL FILTER (2) Install oil cooler attachment fitting and tighten to 27 N·m (20 ft. lbs.) (Fig. 104). (3) Install oil filter. (4) Connect oil cooler inlet and outlet hoses (Fig. 103). (5) Fill cooling system (Refer to 7 - COOLING STANDARD PROCEDURE - COOLING SYSTEM FILLING). OIL FILTER REMOVAL Fig. 103 Engine Oil Cooler Hoses 1 2 3 4 5 - OIL COOLER INLET TUBE INLET HOSE OIL COOLER OUTLET TUBE OUTLET HOSE WATER PUMP INLET TUBE 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 suitable oil filter wrench, turn filter counterclockwise to remove from oil filter adapter (Fig. 105). Properly discard used oil filter. INSTALLATION INSTALLATION (1) Lubricate seal and position oil cooler to connector fitting on oil filter adapter (Fig. 104). NOTE: Position the flat side of oil cooler parallel to oil pan rail. (1) Wipe oil filter adapter base clean and inspect gasket contact surface. (2) Lubricate gasket of new filter with clean engine oil. (3) Install new filter until gasket contacts base (Fig. 105). Tighten filter 1 turn or 20 N·m (15 ft. lbs.). Use filter wrench if necessary. (4) Start engine and check for leaks. ENGINE 3.3/3.8L RS OIL FILTER ADAPTER 9 - 141 (8) Turn off engine and check oil level. Adjust oil level as necessary. REMOVAL (1) Raise vehicle on hoist. (2) Remove the oil filter. (3) Disconnect oil pressure switch electrical connector. (4) Remove oil filter adapter attaching bolts (Fig. 105). (5) Remove oil filter adapter and seal (Fig. 105). OIL PAN REMOVAL (1) Disconnect negative cable from battery and remove engine oil dipstick. (2) Raise vehicle on hoist and drain engine oil. (3) Remove drive belt splash shield. (4) Remove strut to transaxle attaching bolt (Fig. 106). Loosen strut to engine block attaching bolts. (5) Remove transaxle case cover (Fig. 106). Fig. 105 OIL FILTER ADAPTER 1 2 3 4 5 6 - SEAL OIL FILTER ADAPTER OIL FILTER BOLT OIL PRESSURE SWITCH BOLT INSTALLATION (1) Clean oil filter adapter and install new seal. (2) Position adapter on engine block and install bolts (Fig. 105). (3) Tighten adapter bolts to 28 N·m (250 in. lbs.). (4) Connect oil pressure switch electrical connector (Fig. 105). (5) Install the oil filter. (6) Lower vehicle on hoist. (7) Start engine and allow to run approximately 2 minutes. Fig. 106 Powertrain Struts and Transaxle Case Cover 1 2 3 4 5 6 7 8 9 - BRACKET - ENGINE REAR MOUNT BOLT - TRANSAXLE CASE COVER STRUT - TRANSAXLE TO ENGINE HORIZONTAL BOLT - HORIZONTAL STRUT BOLT - STRUT TO TRANSAXLE COVER - TRANSAXLE CASE LOWER STRUT - TRANSAXLE TO ENGINE BOLT - STRUT TO ENGINE BOLT - ENGINE REAR MOUNT BRACKET (6) Remove oil pan fasteners (Fig. 107). (7) Remove the oil pan and gasket (Fig. 107). CLEANING (1) Clean oil pan with solvent and wipe dry with a clean cloth. (2) Clean all gasket material from mounting surfaces of pan and block. 9 - 142 ENGINE 3.3/3.8L RS OIL PAN (Continued) Fig. 108 Oil Pan Sealing 1 - SEALER LOCATIONS (8) Connect negative cable to battery. (9) Fill crankcase with oil to proper level. OIL PRESSURE RELIEF VALVE Fig. 107 OIL PAN 1 2 3 4 - GASKET BOLT OIL PAN NUT (3) Clean oil screen and pick-up tube in clean solvent. REMOVAL (1) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (2) Drill a 3.175 mm (1/8 in.) hole in the center of the retainer cap (Fig. 109). Insert a self-threading sheet metal screw into the cap. (3) Using suitable pliers, remove cap and discard. (4) Remove spring and relief valve (Fig. 109). INSPECTION (1) Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary. Install a new drain plug gasket. Tighten to 27 N·m (20 ft. lbs.). (2) Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. (3) Inspect condition of oil screen and pick-up tube. INSTALLATION (1) Clean sealing surfaces and apply a 1/8 inch bead of Mopart Engine RTV GEN II at the parting line of the chain case cover and the rear seal retainer (Fig. 108). (2) Position a new pan gasket on oil pan (Fig. 107). (3) Install oil pan and tighten fasteners to 12 N·m (105 in. lbs.) (Fig. 107). (4) Install cover to transaxle case (Fig. 106). (5) Install the strut bolt to transaxle housing (Fig. 106). Tighten all bending brace bolts. (6) Install the drive belt splash shield. (7) Lower vehicle and install oil dipstick. Fig. 109 Oil Pressure Relief Valve 1 - RELIEF VALVE 2 - SPRING 3 - RETAINER CAP ENGINE 3.3/3.8L RS 9 - 143 OIL PRESSURE RELIEF VALVE (Continued) INSTALLATION (1) Clean relief valve, spring and bore. NOTE: Lubricate relief valve with clean engine oil before installing. (2) Install relief valve and spring into housing. (3) Install new retainer cap until flush with sealing surface. (4) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (5) Fill crankcase with proper oil to correct level. OIL PRESSURE SWITCH DESCRIPTION The engine oil pressure switch is located on the lower left front side of the engine. It screws into the oil filter adapter. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. OPERATION The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator light. The switch receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa (4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light. For wiring circuits and diagnostic information, (Refer to Appropriate Wiring/Diagnostic Information). REMOVAL (1) Raise vehicle on hoist. (2) Disconnect electrical connector from switch. (3) Remove oil pressure switch (Fig. 110). INSTALLATION (1) Install oil pressure switch. Torque oil pressure switch to 23 N·m (200 in. lbs.) (Fig. 110). (2) Connect electrical connector to switch. (3) Lower the vehicle. (4) Start engine and check for leaks. (5) Check engine oil level. Adjust as necessary. Fig. 110 OIL FILTER ADAPTER 1 2 3 4 5 6 - SEAL OIL FILTER ADAPTER OIL FILTER BOLT OIL PRESSURE SWITCH BOLT OIL PUMP DESCRIPTION The oil pump is located in the timing chain cover. It is driven by the crankshaft. REMOVAL The oil pump is contained within the timing chain cover housing (Fig. 111). (1) Remove oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL) (2) Remove the timing chain cover. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (3) Disassemble oil pump from timing chain cover. (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP DISASSEMBLY) (4) Clean and Inspect oil pump components. (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - CLEANING) (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - INSPECTION) 9 - 144 ENGINE 3.3/3.8L RS OIL PUMP (Continued) DISASSEMBLY INSPECTION (1) Remove oil pump cover screws, and lift off cover (Fig. 111). (2) Remove oil pump rotors (Fig. 111). (3) Clean and inspect oil pump components. (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - CLEANING) (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - INSPECTION) (1) Inspect mating surface of the chain case cover. Surface should be smooth. Replace cover if scratched or grooved. (2) Lay a straightedge across the pump cover surface (Fig. 112). If a 0.025 mm (0.001 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced. (3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 7.64 mm (0.301 in.) or less (Fig. 113), or if the diameter is 79.95 mm (3.148 in.) or less, replace outer rotor. (4) If inner rotor thickness measures 7.64 mm (0.301 in.) or less, replace inner rotor (Fig. 114). Fig. 111 OIL PUMP 1 2 3 4 5 - TIMING CHAIN COVER SCREWS INNER ROTOR OUTER ROTOR COVER CLEANING (1) Clean all parts thoroughly in a suitable solvent. Fig. 112 Checking Oil Pump Cover Flatness 1 - FEELER GAUGE 2 - OIL PUMP COVER 3 - STRAIGHT EDGE (5) Install outer rotor into chain case cover. Press rotor to one side with fingers and measure clearance between rotor and chain case cover (Fig. 115). If measurement is 0.39 mm (0.015 in.) or more, replace chain case cover, only if outer rotor is in specification. (6) Install inner rotor into chain case cover. If clearance between inner and outer rotors (Fig. 116) is 0.203 mm (0.008 in.) or more, replace both rotors. (7) Place a straightedge across the face of the chain case cover, between bolt holes. If a feeler gauge of 0.10 mm (0.004 in.) or more can be inserted between rotors and the straightedge, replace pump assembly (Fig. 117). ONLY if rotors are in specs. ENGINE 3.3/3.8L RS 9 - 145 OIL PUMP (Continued) Fig. 113 Measuring Outer Rotor Thickness Fig. 116 Measuring Clearance Between Rotors 1 - FEELER GAUGE 2 - INNER ROTOR 3 - OUTER ROTOR Fig. 114 Measuring Inner Rotor Thickness Fig. 117 Measuring Clearance Over Rotors 1 - FEELER GAUGE 2 - STRAIGHT EDGE Fig. 115 Measuring Outer Rotor Clearance in Housing 1 - FEELER GAUGE 2 - OUTER ROTOR (8) Remove oil pressure relief valve. (Refer to 9 ENGINE/LUBRICATION/OIL PRESSURE RELIEF VALVE - REMOVAL) (9) Inspect oil pressure relief valve and bore. Inspect for scoring, pitting and free valve operation in bore (Fig. 118). Small marks may be removed with 400-grit wet or dry sandpaper. (10) The relief valve spring has a free length of approximately 49.5 mm (1.95 inches) it should test between 19.5 and 20.5 pounds when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet specifications. 9 - 146 ENGINE 3.3/3.8L RS OIL PUMP (Continued) (11) If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss. Fig. 118 Oil Pressure Relief Valve 1 - RELIEF VALVE 2 - SPRING 3 - RETAINER CAP ASSEMBLY (1) Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover. (2) Prime oil pump before installation by filling rotor cavity with engine oil. (3) Install cover and tighten screws to 12 N·m (105 in. lbs.). (4) If removed, install the oil pressure relief valve. (Refer to 9 - ENGINE/LUBRICATION/OIL PRESSURE RELIEF VALVE - INSTALLATION) INSTALLATION (1) Install oil pump. (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - ASSEMBLY) (2) Install timing chain cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) and oil pan (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). INTAKE MANIFOLD DESCRIPTION The intake system is made up of an upper and lower intake manifold. The upper intake manifold is made of a composite for both the 3.3L engine and for the 3.8L engine (Fig. 123). The lower intake manifold is common between the two engines (Fig. 127). It also provides coolant crossover between cylinder heads and houses the coolant thermostat (Fig. 127). The intake manifold utilizes a compact design with very low restriction and outstanding flow balance. This design allows the engine to perform with a wide torque curve while increasing higher rpm horsepower. If, for some reason, the molded-in vacuum ports break, the composite manifold can be salvaged. The vacuum ports are designed to break at the shoulder, if overloaded. Additional material in the shoulder area provides sufficient stock to repair. For more information and procedure, (Refer to 9 - ENGINE/ MANIFOLDS/INTAKE MANIFOLD - STANDARD PROCEDURE). Also, if the special screws that attach the MAP sensor, power steering reservoir, throttle cable bracket, and the EGR tube become stripped, an oversized screw is available to repair the stripped-out condition. For more information and procedure, (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - STANDARD PROCEDURE) OPERATION The intake manifold delivers air to the combustion chambers. This air allows the fuel delivered by the fuel injectors to ignite when the spark plugs fire. DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. 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. INTAKE MANIFOLD - UPPER STANDARD PROCEDURE STANDARD PROCEDURE - MANIFOLD STRIPPED THREAD REPAIR The composite upper intake manifold thread bosses, if stripped out, can be repaired by utilizing a ENGINE 3.3/3.8L RS 9 - 147 INTAKE MANIFOLD - UPPER (Continued) repair screw available through Mopart parts. Repair screws are available for the following manifold attached components: • MAP sensor • Power steering reservoir • EGR tube • Throttle cable bracket The repair screws require a unique tightening torque specification from the original screw. Refer to the following chart for specification. DESCRIPTION (2) Drill out the nipple (port) base using a 7/16” (brake booster port) or 11/32” (LDP/speed control port ) drill bit (Fig. 119). (3) Using a 1/4”–18 NPT (brake booster port) or 1/8”–18 NPT (LDP/speed control port ) pipe tap, cut internal threads (Fig. 119). Use caution to start tap in a axis same as original nipple. (4) Apply Mopart Thread Sealant to threads of repair nipple(s). (5) Install repair nipple(s). Do not over torque repair nipple(s). TORQUE* STRIP-OUT REPAIR SCREWS ONLY MAP Sensor Repair Screw 4 N·m (35 in. lbs.) Power Steering Reservoir Repair Screw 9 N·m (80 in. lbs.) EGR Tube Attaching Repair Screw 9 N·m (80 in. lbs.) Throttle Cable Bracket Repair Screw 9 N·m (80 in. lbs.) *Install Slowly Using Hand Tools Only STANDARD PROCEDURE - INTAKE MANIFOLD VACUUM PORT REPAIR The composite intake manifold vacuum ports can be repaired. Although, if the manifold plenum chamber is damaged or cracked, the manifold must be replaced. To repair a broken or damaged vacuum nipple (port) on the composite intake manifold, perform the following procedure: PARTS REQUIRED · Brass Nipple – 1/49 O.D. x 1/89 pipe thread (LDP/Speed Control Port) · Brass Nipple – 1/29 O.D. x 1/49 pipe thread (Brake Booster Port) TOOLS REQUIRED · Pipe Tap – 1/89 - 18 NPT Fig. 119 Intake Manifold Port Repair 1 1 2 2 3 - BRAKE BOOSTER PORT = 1/49–18 NPT PIPE TAP LDP/SPEED CONTROL PORT = 1/89–18 NPT PIPE TAP DRILL BIT = 7/169 BRAKE BOOSTER PORT DRILL BIT = 11/329 LDP/SPEED CONTROL PORT INTAKE MANIFOLD · Drill Bit – 11/329 · File/Sandpaper REMOVAL - UPPER INTAKE MANIFOLD · Pipe Tap – 1/49 - 18 NPT (1) Disconnect battery negative cable. (2) Disconnect inlet air temperature (IAT) sensor electrical connector. (3) Remove air inlet resonator to throttle body hose assembly. (4) Disconnect throttle and speed control cables from throttle body (Refer to 14 - FUEL SYSTEM/ FUEL INJECTION/THROTTLE CONTROL CABLE REMOVAL). (5) Disconnect make-up air hose support clip from throttle cable bracket. (6) Disconnect the automatic idle speed (AIS) motor and throttle position sensor (TPS) wiring connectors from throttle body. · Drill Bit – 7/169 · File/Sandpaper NOTE: While performing this procedure, avoid getting the manifold material residue into the plenum chamber. (1) File or sand the remaining port back until a flat surface is obtained (plane normal to nipple (port) axis). 9 - 148 ENGINE 3.3/3.8L RS INTAKE MANIFOLD - UPPER (Continued) (7) Disconnect the manifold absolute pressure (MAP) sensor electrical connector. (8) Disconnect the vapor purge vacuum hose from throttle body. (9) Disconnect the PCV hose (Fig. 120). Fig. 121 POWER STEERING FLUID RESERVOIR 1 - POWER STEERING RESERVOIR 2 - BOLT - RESERVOIR TO MANIFOLD 3 - NUT - RESERVOIR TO COIL BRACKET Fig. 120 PCV & HOSE 1 - HOSE - PCV 2 - PCV VALVE (10) Remove the power steering reservoir attaching bolts and only loosen the nut (Fig. 121). Lift reservoir up to disengage lower mount from stud. Set reservoir aside. Do not disconnect hose. (11) Disconnect the brake booster and leak detection pump (LDP) hoses from intake manifold (Fig. 122). (12) Remove intake manifold bolts and remove the manifold (Fig. 123). (13) Cover the lower intake manifold with a suitable cover while the upper manifold is removed. (14) Clean and inspect the upper intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - CLEANING) and (Refer to 9 - ENGINE/ MANIFOLDS/INTAKE MANIFOLD - INSPECTION). CLEANING (1) Discard gasket(s). (2) Clean all sealing surfaces. Fig. 122 BRAKE BOOSTER & LDP VACUUM HOSES 1 - LDP & SPEED CONTROL VACUUM HOSE 2 - BRAKE BOOSTER VACUUM HOSE 3 - MAP SENSOR ENGINE 3.3/3.8L RS 9 - 149 INTAKE MANIFOLD - UPPER (Continued) • MAP sensor - 1.7 N·m (15 in. lbs.) • Throttle cable bracket - 5.6 N·m (50 in. lbs.) (2) Remove covering on lower intake manifold and clean surfaces. (3) Inspect manifold gasket condition. Gaskets can be re-used, if not damaged. To replace, remove gasket from upper manifold (Fig. 123). Position new gasket in seal channel and press lightly in-place. Repeat procedure for each gasket position. (4) Position upper manifold on lower manifold (Fig. 123). Install and tighten bolts to 12 N·m (105 in. lbs.) following torque sequence in (Fig. 124). Fig. 123 INTAKE MANIFOLD - UPPER 1 2 3 4 5 6 - BOLT MAP SENSOR SCREW MANIFOLD - UPPER WIRE HARNESS GASKET (3 PER CYL. BANK) INSPECTION Check manifold for: • Damage and cracks. • Mounting surface distortion by using a straightedge and thickness gauge. INSTALLATION - UPPER INTAKE MANIFOLD (1) If the following components were removed from manifold, install and tighten to specifications: CAUTION: The special screws used for the composite manifold attached components must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available. For more information and procedure (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - STANDARD PROCEDURE - MANIFOLD STRIPPED THREAD REPAIR). Fig. 124 UPPER MANIFOLD TIGHTENING SEQUENCE (5) Connect the MAP sensor electrical connector. (6) Connect the brake booster and LDP vacuum hose to intake manifold (Fig. 122). CAUTION: The special screws used for attaching the EGR tube and power steering reservoir to the manifold must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available. For more information and procedure (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - STANDARD PROCEDURE - MANIFOLD STRIPPED THREAD REPAIR). (7) Install the power steering reservoir (Fig. 121). Tighten screws to manifold to 5.6 N·m (50 in. lbs.). (8) Connect throttle and speed control cables to throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE CONTROL CABLE INSTALLATION) (9) Attach make up air hose clip into the hole in the throttle cable bracket. (10) Connect the wiring connectors to the throttle position sensor (TPS) and Automatic Idle Speed (AIS) motor. 9 - 150 ENGINE 3.3/3.8L RS INTAKE MANIFOLD - UPPER (Continued) (11) Install air cleaner and air inlet hose assembly. (12) Connect the inlet air temperature (IAT) sensor electrical connector. (13) Connect battery negative cable. INTAKE MANIFOLD - LOWER REMOVAL - LOWER INTAKE MANIFOLD (1) Perform fuel system pressure release procedure (before attempting any repairs). (Refer to 14 FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE) (2) Drain the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (3) Remove the upper intake manifold. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL) (4) Remove the fuel line. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES - STANDARD PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) (5) Remove ignition coil and bracket (Fig. 125). (6) Disconnect heater supply hose and engine coolant temperature sensor (Fig. 126). (7) Disconnect the fuel injector wire harness. (8) Remove the fuel injectors and rail assembly (Fig. 125). (9) Remove radiator upper hose. (10) Remove the intake manifold bolts. (11) Remove lower intake manifold (Fig. 127). WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE. (12) Remove intake manifold seal retainers screws (Fig. 127). Remove intake manifold gasket. (13) Inspect and clean manifold. (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/ INTAKE MANIFOLD - CLEANING) CLEANING (1) Discard gasket(s). (2) Clean all sealing surfaces. INSPECTION Check for: • Damage and cracks of each section. • Clogged water passages in end cross-overs (if equipped). • Check for cylinder head mounting surface distortion using a straightedge and thickness gauge. (Refer to 9 - ENGINE/CYLINDER HEAD - INSPECTION) Fig. 125 FUEL RAIL AND IGNITION COIL & BRACKET 1 - FUEL RAIL 2 - BOLT - FUEL RAIL 3 - NUT - IGNITION COIL 4 - BOLT - IGNITION COIL 5 - IGNITION COIL 6 - BRACKET - IGNITION COIL 7 - STUD - IGNITION COIL 8 - SEPARATOR - SPARK PLUG CABLE 9 - BRACKET - SPARK PLUG CABLE SEPARATOR 10 - BOLT - SEPARATOR BRACKET 11 - BRACKET - SPARK PLUG CABLE SEPARATOR INSTALLATION - LOWER INTAKE MANIFOLD (1) Place a bead (approximately 1/4 in. diameter) of Mopart Engine RTV GEN II onto each of the four manifold to cylinder head gasket corners (Fig. 128). (2) Carefully install the new intake manifold gasket (Fig. 127). Tighten end seal retainer screws to 12 N·m (105 in. lbs.). (3) Install lower intake manifold (Fig. 127). Install the bolts and torque to 1 N·m (10 in. lbs.). Then torque bolts to 22 N·m (200 in. lbs.) in sequence shown in (Fig. 129). Then torque again to 22 N·m (200 in. lbs.). After intake manifold is in place, inspect to make sure seals are in place. (4) Install the fuel injectors and rail assembly. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/ FUEL RAIL - INSTALLATION) (5) Connect fuel injector electrical harness. ENGINE 3.3/3.8L RS 9 - 151 INTAKE MANIFOLD - LOWER (Continued) Fig. 126 ECT SENSOR & HEATER SUPPLY 1 - ENGINE COOLANT TEMPERATURE SENSOR 2 - CONNECTOR - ENGINE COOLANT SENSOR 3 - FITTING - HEATER SUPPLY (6) Connect the engine coolant temperature sensor (Fig. 126). (7) Connect the heater supply (Fig. 126) and radiator upper hoses to manifold. (8) Connect the fuel line. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) (9) Install the upper intake manifold. (Refer to 9 ENGINE/MANIFOLDS/INTAKE MANIFOLD INSTALLATION) (10) Connect negative battery cable. (11) Fill the cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) Fig. 127 INTAKE MANIFOLD - LOWER 1 2 3 4 - INTAKE MANIFOLD - LOWER BOLT - GASKET END SEAL RETAINER GASKET BOLT - LOWER INTAKE MANIFOLD Fig. 128 Intake Manifold Gasket Sealing 1 - SEALER LOCATIONS 9 - 152 ENGINE 3.3/3.8L RS INTAKE MANIFOLD - LOWER (Continued) Fig. 129 LOWER MANIFOLD TIGHTENING SEQUENCE EXHAUST MANIFOLD DESCRIPTION Fig. 130 CROSS-OVER PIPE 1 2 3 4 - CROSS-OVER PIPE BOLT GASKET FLAG NUT The exhaust manifolds are log type and made of Hi-Sil-Moly (high temperature resistant) nodular cast iron. The exhaust manifolds are attached directly to the cylinder heads and a cross-over pipe connects the two manifolds. OPERATION The exhaust manifolds collects the exhaust gases exiting the combustion chambers. It then channels the exhaust gases to the exhaust pipe that is attached to the rear (right side) manifold. EXHAUST MANIFOLD - RIGHT REMOVAL (1) Disconnect battery negative cable. (2) Remove the wiper module. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL) (3) Disconnect spark plug wires. (4) Remove bolts fastening crossover pipe to exhaust manifold (Fig. 130). (5) Disconnect and remove the upstream oxygen sensor (Fig. 133). (6) Remove the heat shield attaching screws (Fig. 133). (7) Remove the upper heat shield (Fig. 133). (8) Raise vehicle on hoist and remove drive belt shield. (9) Loosen the power steering pump support strut lower bolt (Fig. 131). (10) Disconnect downstream oxygen sensor connector. Fig. 131 P/S PUMP STRUT 1 - BOLT - LOWER 2 - STRUT - P/S PUMP 3 - BOLT - UPPER (11) Disconnect catalytic converter pipe from exhaust manifold (Fig. 132). (12) Lower vehicle and remove the power steering pump support strut upper bolt (Fig. 131). (13) Remove bolts attaching exhaust manifold to cylinder head and remove manifold (Fig. 133). (14) Inspect and clean manifold. (Refer to 9 ENGINE/MANIFOLDS/EXHAUST MANIFOLD CLEANING) (Refer to 9 - ENGINE/MANIFOLDS/ EXHAUST MANIFOLD - INSPECTION) CLEANING (1) Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head. ENGINE 3.3/3.8L RS 9 - 153 EXHAUST MANIFOLD - RIGHT (Continued) surface and exhaust crossover mounting surface with a straightedge and thickness gauge (Fig. 134). Manifold surface flatness limits should not exceed 1.0 mm (0.039 in.). Fig. 134 Check Exhaust Manifold Mounting Fig. 132 Catalytic Converter to Exhaust Manifold 1 2 3 4 - FLAG NUT GASKET BOLT CATALYTIC CONVERTER 1 - STRAIGHT EDGE 2 - CROSSOVER PIPE MOUNTING SURFACE 3 - FEELER GAUGE INSTALLATION (1) Position exhaust manifold on cylinder head and install bolts to center runner (cylinder #3) and initial tighten to 2.8 N·m (25 in. lbs.) (Fig. 133) (2) Using a new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 41 N·m (30 ft. lbs.) (Fig. 130). NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. The cross-over bolts are made of a special stainless steel alloy. If replacement is required, OEM bolts are highly recommended. Fig. 133 EXHAUST MANIFOLD - RIGHT 1 2 3 4 5 6 - SCREW - HEAT SHIELD HEAT SHIELD - UPPER BOLT - EXHAUST MANIFOLD HEAT SHIELD - LOWER EXHAUST MANIFOLD - RIGHT OXYGEN SENSOR - UPSTREAM INSPECTION Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting (3) Install the remaining manifold attaching bolts. Tighten all bolts to 23 N·m (200 in. lbs.). (4) Position the power steering pump support strut and install upper bolt (Fig. 131). (5) Install heat shield and attaching screws (Fig. 133). (6) Install and connect upstream oxygen sensor (Fig. 133). (7) Raise the vehicle. (8) Attach catalytic converter pipe to exhaust manifold using new gasket and tighten bolts to 37 N·m (27 ft. lbs.) (Fig. 132). (9) Connect downstream oxygen sensor connector. (10) Tighten the power steering pump support strut lower bolt (Fig. 131). (11) Install the belt splash shield and lower the vehicle. 9 - 154 ENGINE 3.3/3.8L RS EXHAUST MANIFOLD - RIGHT (Continued) (12) Install the wiper module. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION) (13) Connect battery negative cable. EXHAUST MANIFOLD - LEFT REMOVAL (1) Disconnect battery negative cable. (2) Remove bolts attaching crossover exhaust manifold (Fig. 135). pipe to Fig. 136 EXHAUST MANIFOLD - LEFT 1 2 3 4 - EXHAUST MANIFOLD - LEFT BANK HEAT SHIELD NUT - HEAT SHIELD BOLT - EXHAUST MANIFOLD Fig. 135 CROSS-OVER PIPE 1 2 3 4 - CROSS-OVER PIPE BOLT GASKET FLAG NUT (3) Disconnect left cylinder bank spark plug wires. (4) Remove heat shield attaching bolts (Fig. 136). (5) Remove bolts attaching exhaust manifold to cylinder head (Fig. 136). (6) Remove the exhaust manifold (Fig. 136). (7) Inspect and clean manifold. (Refer to 9 ENGINE/MANIFOLDS/EXHAUST MANIFOLD INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/ EXHAUST MANIFOLD - CLEANING) CLEANING (1) Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head. INSPECTION Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge (Fig. 137). Manifold surface flatness limits should not exceed 1.0 mm (0.039 in.). Fig. 137 Check Exhaust Manifold Mounting 1 - STRAIGHT EDGE 2 - CROSSOVER PIPE MOUNTING SURFACE 3 - FEELER GAUGE INSTALLATION (1) Position exhaust manifold on cylinder head (Fig. 136). Install bolts to center runner (cylinder #4) and initial tighten to 2.8 N·m (25 in. lbs.). (2) Using a new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 41 N·m (30 ft. lbs.) (Fig. 135). NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. The cross-over bolts are made of a special stainless steel alloy. If replacement is required, OEM bolts are highly recommended. ENGINE 3.3/3.8L RS 9 - 155 EXHAUST MANIFOLD - LEFT (Continued) (3) Position heat shield on manifold (Fig. 136). (4) Install the remaining manifold attaching bolts. Tighten all bolts to 23 N·m (200 in. lbs.). (5) Install and tighten heat shield attaching nut to 12 N·m (105 in. lbs.) (Fig. 136). (6) Connect battery negative cable. VALVE TIMING STANDARD PROCEDURE STANDARD PROCEDURE - VALVE TIMING VERIFICATION (1) Remove front cylinder head cover and all 6 spark plugs. (2) Rotate engine until the #2 piston is at TDC of the compression stroke. (3) Install a degree wheel on the crankshaft pulley. (4) With proper adaptor, install a dial indicator into #2 spark plug hole. Using the indicator find TDC on the compression stroke. (5) Position the degree wheel to zero. (6) Remove dial indicator from spark plug hole. (7) Place a 5.08 mm (0.200 in.) spacer between the valve stem tip of #2 intake valve and rocker arm pad. Allow tappet to bleed down to give a solid tappet effect. (8) Install a dial indicator so plunger contacts the #2 intake valve spring retainer as nearly perpendicular as possible. Zero the indicator. (9) Rotate the engine clockwise until the intake valve has lifted .254 mm (0.010 in.). CAUTION: Do not turn crankshaft any further clockwise as intake valve might bottom and result in serious damage. (10) Degree wheel should read 6 degrees BTDC to 6 degrees ATDC. STANDARD PROCEDURE - MEASURING TIMING CHAIN WEAR NOTE: This procedure must be performed with the timing chain cover removed (Refer to 9 - ENGINE/ VALVE TIMING/TIMING CHAIN COVER - REMOVAL). (1) Position a scale next to timing chain so that any movement of chain may be measured (Fig. 138). (2) Position a torque wrench and socket on the camshaft sprocket attaching bolt. Apply force in the direction of crankshaft rotation to take up slack to the following torque: • 41 N·m (30 ft. lb.) with cylinder heads installed • 20 N·m (15 ft. lb.) with cylinder heads removed NOTE: With torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block crankshaft to prevent rotation. (3) Holding a measuring scale along edge of chain links (Fig. 138). (4) Apply force in the reverse direction to the following torque: • 41 N·m (30 ft. lb.) with cylinder heads installed • 20 N·m (15 ft. lb.) with cylinder heads removed (5) Measure amount of sprocket/chain movement. (6) Install a new timing chain and sprockets if movement exceeds 3.175 mm (1/8 in.). Fig. 138 Measuring Timing Chain Wear 1 - TORQUE WRENCH TIMING CHAIN COVER REMOVAL (1) Disconnect negative cable from battery. (2) Drain cooling system. (Refer to 7 - COOLING STANDARD PROCEDURE) (3) Raise vehicle on hoist. (4) Drain engine oil. (5) Remove right wheel and inner splash shield. (6) Remove oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL) (7) Remove oil pick-up tube (Fig. 139). (8) Remove accessory drive belt. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL) (9) Remove A/C compressor and set aside. (10) Remove crankshaft vibration damper. (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) (11) Remove radiator lower hose. 9 - 156 ENGINE 3.3/3.8L RS TIMING CHAIN COVER (Continued) Fig. 139 OIL PICKUP TUBE 1 - BOLT 2 - OIL PICK-UP TUBE 3 - O-RING (12) Remove heater hose from timing chain cover housing (Fig. 140) or water pump inlet tube (if engine oil cooler equipped) (Fig. 141). Fig. 141 HEATER HOSES 3.3/3.8L (With Engine Oil Cooler) 1 2 3 4 5 6 - HOSE - HEATER SUPPLY HOSE - HEATER RETURN TUBE ASSEMBLY - HEATER RETURN BOLT - TUBE ASSEMBLY BOLT - TUBE ASSEMBLY HOSE - HEATER RETURN/OIL COOLER OUTLET (13) Remove the right side engine mount. (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL) (14) Remove idler pulley from engine bracket (Fig. 142). (15) Remove the engine mount bracket (Fig. 142). (16) Remove camshaft position sensor from timing chain cover (Fig. 142). (17) Remove the water pump for cover removal clearance. (Refer to 7 - COOLING/ENGINE/WATER PUMP - REMOVAL) (18) Remove the bolt attaching the power steering pump support strut to the front cover (Fig. 143). (19) Remove the timing chain cover fasteners. Remove timing chain cover (Fig. 144). INSTALLATION Fig. 140 HEATER RETURN HOSE (Without Engine Oil Cooler) 1 2 3 4 - CAP AND CLAMP (OIL COOLER EQUIPPED ONLY) HOSE ASSEMBLY - HEATER RETURN BOLT - HEATER TUBE ATTACHING BOLT - HEATER TUBE ATTACHING (1) Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed to insure correct oil pump engagement. NOTE: DO NOT USE SEALER ON COVER GASKET (2) Position new gasket on timing cover (Fig. 144). Adhere new gasket to chain case cover, making sure that the lower edge of the gasket is flush to 0.5 mm (0.020 in.) passed the lower edge of the cover. ENGINE 3.3/3.8L RS 9 - 157 TIMING CHAIN COVER (Continued) Fig. 144 Timing Chain Cover and Gasket 1 - GASKET 2 - TIMING CHAIN COVER Fig. 142 Engine Mount Bracket 1 2 3 4 5 6 7 8 9 - CAMSHAFT SENSOR BOLT - CAMSHAFT SENSOR BOLT - MOUNT BRACKET (VERTICAL) BRACKET - ENGINE MOUNT BOLT - MOUNT BRACKET (HORIZONTAL) PULLEY - IDLER BOLT - IDLER PULLEY SPACER - IDLER PULLEY BOLT BOLT - MOUNT BRACKET (HORIZONTAL) Fig. 143 Power Steering Pump Strut 1 - BOLT - LOWER 2 - STRUT - P/S PUMP 3 - BOLT - UPPER (3) Rotate crankshaft so that the oil pump drive flats are in the vertical position. (4) Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats (Fig. 144). CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result. (5) Install timing cover (Fig. 144). (6) Install timing chain cover bolts. Tighten M8 bolts to 27 N·m (20 ft. lbs.) and M10 bolts to 54 N·m (40 ft. lbs.) (Fig. 145). (7) Install crankshaft front oil seal. (Refer to 9 ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION) (8) Install water pump and pulley. (Refer to 7 COOLING/ENGINE/WATER PUMP - INSTALLATION) (9) Install crankshaft vibration damper. (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER INSTALLATION) (10) Install engine mount bracket (Fig. 142) and tighten M10 to 54 N·m (40 ft. lbs.), M8 bolt to 28 N·m (21 ft. lb. lbs.). (11) Install idler pulley on engine mount bracket (Fig. 142). (12) Install right side engine mount. (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION) (13) Install camshaft position sensor (Refer to 8 ELECTRICAL/IGNITION CONTROL/CAMSHAFT POSITION SENSOR - INSTALLATION). (14) Connect the heater return hose at rear of timing chain cover (Fig. 140) or at water pump inlet tube (if engine oil cooler equipped) (Fig. 141). (15) Connect the radiator lower hose. (16) Install A/C compressor. (17) Install accessory drive belt. (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION) 9 - 158 ENGINE 3.3/3.8L RS TIMING CHAIN COVER (Continued) Fig. 145 TIMING CHAIN COVER BOLT LOCATIONS 1 - BOLT - M8 x 1.25 x 95 2 - BOLT - M10 x 1.5 x 100 3 - BOLT - M10 x 1.5 x 85 (18) Install oil pump pick-up tube with new O-ring. Tighten attaching bolt to 28 N·m (250 in. lbs.). (19) Install oil pan. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION) (20) Install inner splash shield and right front wheel. 4 - BOLT - M8 x 1.25 x 80 5 - BOLT - M8 x 1.25 x 45 (21) Fill crankcase with engine oil to proper level. (22) Fill cooling system. (Refer to 7 - COOLING STANDARD PROCEDURE) (23) Connect negative cable to battery. ENGINE 3.3/3.8L RS TIMING CHAIN AND SPROCKETS REMOVAL REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET 9 - 159 REMOVAL - CRANKSHAFT SPROCKET (1) Remove the timing chain. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (2) Using Special Tools 8539, 5048-6, and 5048-1, remove the crankshaft sprocket while holding the crankshaft from turning (Fig. 147). Be careful not to damage the crankshaft surfaces. (1) Disconnect negative cable from battery. (2) Remove the timing chain cover. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (3) Rotate engine by turning crankshaft until the timing marks are aligned as shown in (Fig. 146). (4) Remove camshaft sprocket attaching bolt. (5) Remove the timing chain with camshaft sprocket. (6) Remove the crankshaft sprocket. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) Fig. 147 CRANKSHAFT SPROCKET - REMOVAL 1 2 3 4 5 - SPECIAL TOOL 5048-6 SPECIAL TOOL 5048-1 SPECIAL TOOL 8450 CRANKSHAFT SPROCKET SPECIAL TOOL 8539 INSTALLATION INSTALLATION - CRANKSHAFT SPROCKET (1) Position the sprocket on the crankshaft (timing mark out) with the timing slot aligned with the timing pin. (2) Install sprocket using Special Tool 8452 (Fig. 148). Install sprocket until it is fully seats on the crankshaft. (3) Install the timing chain and camshaft sprocket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) INSTALLATION - TIMING CHAIN AND CAMSHAFT SPROCKET Fig. 146 Timing Mark Alignment 1 2 3 4 - CAMSHAFT SPROCKET TIMING MARK (DOT) - PLATED LINK - CRANKSHAFT SPROCKET TIMING MARK (DOT) - ARROWS (1) Rotate crankshaft so the timing arrow is to the 12 o’clock position (Fig. 146). NOTE: Lubricate timing chain and sprockets with clean engine oil before installation. (2) While holding camshaft sprocket and chain in hand, place timing chain around the sprocket, aligning the plated link with the dot on the sprocket. Position the timing arrow to the 6 o’clock position (Fig. 146). 9 - 160 ENGINE 3.3/3.8L RS TIMING CHAIN AND SPROCKETS (Continued) (3) Place timing chain around crankshaft sprocket with the plated link lined up with the dot on the sprocket. Install camshaft sprocket into position. (4) Use a straight edge to check alignment of timing marks. (5) Install camshaft sprocket bolt and washer. Tighten bolt to 54 N·m (40 ft. lbs.). (6) Rotate crankshaft 2 revolutions and check timing mark alignment (Fig. 146). If timing marks do not line up, remove camshaft sprocket and realign. (7) Install the timing chain cover. (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (8) Connect negative cable to battery. Fig. 148 CRANKSHAFT SPROCKET - INSTALLATION 1 2 3 4 - SPECIAL TOOL 8452-3 SPECIAL TOOL 8452-1 CRANKSHAFT SPROCKET THRUST BEARING / WASHER ENGINE RG 9a - 1 ENGINE TABLE OF CONTENTS page ENGINE 2.5L TURBO DIESEL DESCRIPTION DESCRIPTION - 2.5L COMMON RAIL DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION - ENGINE COVER . . . . . . . . . . 3 REMOVAL REMOVAL - 2.5L DIESEL ENGINE . . . . . . . . . . 3 REMOVAL - ENGINE COVER . . . . . . . . . . . . . 6 INSTALLATION INSTALLATION - 2.5L TURBO DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION - ENGINE COVER . . . . . . . . . . 7 SPECIFICATIONS SPECIFICATIONS - 2.5L COMMON RAIL DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS - TORQUE . . . . . . . . . . . . 10 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 12 CYLINDER HEAD STANDARD PROCEDURE STANDARD PROCEDURE - VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 STANDARD PROCEDURE - MEASURING PISTON PROTRUSION . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21 CAMSHAFT(S) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 CYLINDER HEAD COVER(S) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 CAMSHAFT OIL SEAL(S) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27 ROCKER ARMS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28 HYDRAULIC LIFTERS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30 page ENGINE BLOCK DESCRIPTION . . . . . . . . . . . . . . . . . . . . CRANKSHAFT DESCRIPTION . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - CHECKING CRANKSHAFT END PLAY . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . CYLINDER LINERS DESCRIPTION . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ..................... INSTALLATION . . . . . . . . . . . . . . . . . . . . INTERNAL VACUUM PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . PISTON & CONNECTING ROD DESCRIPTION . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - PISTON RING FITTING . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION ..................... INSTALLATION . . . . . . . . . . . . . . . . . . . . CRANKSHAFT OIL SEAL - FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . VIBRATION DAMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . ENGINE COVER - FRONT DESCRIPTION . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . CRANKSHAFT MAIN BEARINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . CRANKSHAFT OIL SEAL - REAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . OIL PUMP REMOVAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 . . . . . 30 . . . . . 30 . . . . . 31 . . . . . 31 . . . . . 32 . . . . . . . . . . . . . . . . . 33 . 33 . 34 . 34 . . . . . 35 . . . . . 35 . . . . . 35 . . . . . 36 . . . . . . . . . . . . . . . . . 36 . 36 . 38 . 39 . . . . . 41 . . . . . 41 . . . . . 42 . . . . . 42 . . . . . 43 . . . . . 43 . . . . . 43 . . . . . 44 . . . . . 45 . . . . . 46 . . . . . 46 . . . . . 46 . . . . . 46 . . . . . 47 . . . . . 47 9a - 2 ENGINE RG INSTALLATION INSTALLATION . . . . . . . . . . . INSTALLATION . . . . . . . . . . . OIL PRESSURE SENSOR/SWITCH DESCRIPTION . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . OIL TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . OIL PRESSURE RELIEF VALVE DESCRIPTION . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . OIL COOLER & LINES REMOVAL . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . OIL FILTER DESCRIPTION . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . OIL JET DESCRIPTION . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . INTAKE MANIFOLD DESCRIPTION . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . 48 . . . . . . . . . . . . 48 . . . . . . . . . . . . 48 . . . . . . . . . . . . 48 . . . . . . . . . . . . 48 . . . . . . . . . . . . 48 . . . . . . . . . . . . 48 . . . . . . . . . . . . 49 . . . . . . . . . . . . 49 . . . . . . . . . . . . 49 . . . . . . . . . . . . 50 . . . . . . . . . . . . 50 . . . . . . . . . . . . 51 . . . . . . . . . . . . 51 . . . . . . . . . . . . 51 . . . . . . . . . . . . 52 . . . . . . . . . . . . 52 . . . . . . . . . . . . 52 . . . . . . . . . . . . 52 . . . . . . . . . . . . 52 ENGINE 2.5L TURBO DIESEL DESCRIPTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . VALVE TIMING STANDARD PROCEDURE - LOCKING ENGINE 90° AFTER TDC . . . . . . . . . . . . . . . . . . . . . . BALANCE SHAFT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . TIMING BELT / CHAIN COVER(S) REMOVAL REMOVAL - TIMING BELT OUTER COVER . REMOVAL - TIMING BELT INNER COVER . . INSTALLATION INSTALLATION - TIMING BELT OUTER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION - TIMING BELT INNER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIMING BELT IDLER PULLEY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . TMNG BELT/CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS ADJUSTMENT - TIMING BELT TENSIONER TIMING BELT/CHAIN AND SPROCKETS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION DESCRIPTION SPECIFICATION . 53 . 54 . 54 . 55 . 55 . 56 . 56 . 56 . 57 . 58 . 58 . 59 . 59 . 60 . 60 . 61 SPECIFICATION Thermostat Opening 80°C ± 2°C Generator Rating Denso 12V-95A Cooling System Capacity 13.8 Liters W/O Auxiliary Heater 16.6 Liters With Auxiliary Heater Engine Oil Capacity 6.0L W/Filter Change Timing System Belt Driven Camshafts In Cylinder Head Cover Air Intake Dry Filter Fuel Feed Vane Pump Incorporated In Injection Pump Fuel System Direct Fuel Injection 4 Stroke DESCRIPTION - 2.5L COMMON RAIL DIESEL ENGINE This 2.5 Liter (2500cc) four-cylinder “common rail” direct injection engine is an in-line overhead valve diesel engine. This engine utilizes a cast iron cylinder block and an aluminum cylinder head. The engine is turbocharged and intercooled. The engine also has four valves per cylinder and dual overhead camshafts (Fig. 1). . 52 Displacement 2.5L (2499 cc) Combustion Cycle Bore 92.00 Cooling System Water Cooling Stroke 94.00 Injection Pump Rotary Pump and Electronically Managed Lubrication Pressure Lubricated By Rotary Pump Engine Rotation Clockwise Viewed From Front Cover Compression Ratio 17.5:1 Vacuum at Idle 685.8 mm/Hg (27.0 In/Hg) Belt Tension Automatic Belt Tensioner ENGINE RG 9a - 3 ENGINE 2.5L TURBO DIESEL (Continued) DESCRIPTION - ENGINE COVER Fig. 2 ENGINE COVER 1 - ENGINE COVER MOUNTING BOLTS 2 - ENGINE COVER Fig. 1 2.5L COMMON RAIL DIESEL ENGINE The engine cover is a black plastic cover used to cover the top of the engine (Fig. 10). It is used to isolate engine noises. REMOVAL REMOVAL - 2.5L DIESEL ENGINE (1) Disconnect negative battery cable. (2) Remove engine cover (Fig. 2). (Refer to 9 ENGINE - REMOVAL) (3) Remove air cleaner housing, MAF sensor, and air intake tube assembly (Fig. 3). (4) Remove coolant pressure tank pressure cap. (5) Raise vehicle on hoist. (6) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (7) Remove lower splash shield. (8) Remove splash shield side panels. Fig. 3 MASS AIR FLOW (MAF) SENSOR LOCATION 1 2 3 4 - MAF SENSOR ELECTRICAL CONNECTOR - RETAINING CLAMPS - MASS AIR FLOW (MAF) SENSOR - AIR CLEANER HOUSING 9a - 4 ENGINE RG ENGINE 2.5L TURBO DIESEL (Continued) (9) Remove power steering reservoir hose from power steering pump and drain power steering fluid (Fig. 4). (15) Drain coolant system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (16) Remove coolant pressure tank (Fig. 5). Fig. 4 RESERVOIR AND HOSES - 2.5L DIESEL Fig. 5 COOLANT RECOVERY PRESSURE CONTAINER LOCATION 1 - POWER STEERING FLUID RESERVOIR 2 - RESERVOIR BRACKET 3 - SUPPLY HOSE BRACKET 4 - RETURN HOSE FROM GEAR 5 - ROUTING CLIP 6 - PRESSURE HOSE TO GEAR 7 - SUPPLY HOSE (PUMP END) 8 - PRESSURE HOSE (PUMP END) 9 - SUPPLY HOSE 10 - RETURN HOSE (10) Disconnect high pressure line at pump (Fig. 4). (11) Disconnect power steering pump return hose clamp (Fig. 4). (12) Remove power steering return line retaining clamp (Fig. 4). (13) Remove power steering line clamps from oil pan (Fig. 4). (14) Remove power steering pump reservoir and bracket (Fig. 4). 1 - PRESSURE/VENT CAP 2 - BRAKE MASTER CYLINDER 3 - BATTERY 4 - BATTERY SHIELD 5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING CLIP 6 - ENGINE COVER 7 - COOLANT RECOVERY PRESSURE CONTAINER ENGINE RG 9a - 5 ENGINE 2.5L TURBO DIESEL (Continued) (17) Remove battery shield. (18) Remove charge air cooler outlet hose. (19) Remove charge air cooler inlet hose (Fig. 6). Fig. 7 UPPER AND LOWER RADIATOR HOSES Fig. 6 CHARGE AIR COOLER HOSES 1 2 3 4 5 6 7 - COOLING MODULE BYPASS HOSE UPPER RADIATOR HOSE CHARGE AIR COOLER OULET HOSE CHARGE AIR COOLER INLET HOSE LOWER RADIATOR HOSE CHARGE AIR COOLER (20) Disconnect upper radiator hose at engine (Fig. 7). (21) Disconnect lower radiator hose at engine (Fig. 7). (22) Disconnet brake booster vacuum supply hose. (23) Disconnect heater core return hose at engine. (24) Disconnect egr solenoid vacuum line at brake booster check valve. (25) Disconnect fuel injector, cam sensor, boost pressure/intake air temp sensor, fuel rail high pressure, and egr solenoid connectors (Fig. 8). (26) Disconnect generator electrical connectors. (27) Disconnect coolant temp sensor and glow plug electrical connectors. (28) Disconnect injection pump and A/C compressor electrical connectors. (29) Disconnect starter electrical connectors. (30) Disconnect ground wires at engine block. (31) Raise vehicle on hoist. (32) Disconnect oil temp sensor, oil pressure sensor, engine speed sensor, and vehicle speed sensor electrical connector (Fig. 9). 1 2 3 4 5 6 7 - COOLANT BYPASS HOSE RADIATOR ASSEMBLY UPPER RADIATOR HOSE COOLING FAN LOWER RADIATOR HOSE CHARGE AIR COOLER RADIATOR BRACKET (33) Remove front wheels. (34) Remove the suspension cradle assembly (Refer to 13 - FRAME & BUMPERS/FRAME/ENGINE CRADLE CROSSMEMBER - REMOVAL). (35) Remove both axle shaft assemblies (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT REMOVAL). (36) Disconnect the clutch slave cylinder quick disconnect line (RHD only)(Refer to 6 - CLUTCH/SLAVE CYLINDER - REMOVAL). (37) Disconnect reverse lamp connector. (38) Disconnect shifter cables at the tranmission (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL/GEAR SHIFT CABLE - REMOVAL). (39) Disconnect exhaust pipe from the turbocharger downpipe and reposition to right side of vehicle. (40) Disconnect cabin heater coolant line (Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT - REMOVAL). (41) Remove front engine mount bracket retaining bolts from lower radiator support (42) Lower vehicle. Evacuate the A/C system (Refer to 24 - HEATING & AIR CONDITIONING/ 9a - 6 ENGINE RG ENGINE 2.5L TURBO DIESEL (Continued) Fig. 9 REAR ENGINE VIEW Fig. 8 ENGINE COMPONENT LOCATIONS 1 - FUEL INJECTOR RETURN LINE 2 - FUEL INJECTOR SUPPLY LINE 3 - OIL SEPARATOR 4 - FUEL INJECTOR 5 - CAMSHAFT POSITION SENSOR 6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR 7 - EGR SOLENOID 8 - FUEL PRESSURE SENSOR 9 - CYLINDER HEAD COVER/INTAKE MANIFOL 10 - FUEL RAIL 11 - WIRING HARNESS RETAINING CLIPS 1 2 3 4 5 6 - SUSPENSION CRADLE ENGINE BLOCK OIL PRESSURE SWITCH OIL TEMPERATURE SENSOR VEHICLE SPEED SENSOR TRANSMISSION PLUMBING/REFRIGERANT - STANDARD PROCEDURE). (43) Disconnect the A/C lines at the A/C compressor. (44) Disconnect the fuel supply and return lines. (45) Position engine cradle under engine and lower vehicle over cradle. (46) Remove right engine mount bolts. (47) Remove left engine mount through bolt. (48) Raise vehicle, leaving engine and transmission on engine cradle. (49) Lift engine from engine cradle and diassemble as necessary. REMOVAL - ENGINE COVER (1) Remove engine cover retaining bolts. (2) Remove engine cover from engine (Fig. 10). Fig. 10 ENGINE COVER 1 - ENGINE COVER MOUNTING BOLTS 2 - ENGINE COVER RG ENGINE 9a - 7 ENGINE 2.5L TURBO DIESEL (Continued) INSTALLATION INSTALLATION - 2.5L TURBO DIESEL ENGINE (1) Reassembly engine and transmission assembly and install on engine cradle. (2) Position engine and cradle assembly under vehicle. (3) Slowly lower the vehicle down over the engine and cradle assembly. (4) Install right engine mount bolts. Torque to 54N·m (40 ft. lbs.) (5) Install left engine mount through bolt. Torque to 75N·m (55 ft. lbs.) (6) Raise vehicle and engine from engine cradle. (7) Attach front engine mount bracket to lower radiator support. Torque to 54N·m (40 ft. lbs.) (8) Connect cabin heater coolant hose. (9) Connect exhaust pipe to the turbocharger downpipe flange. Torque to 28 N·m (250 in. lbs.) (10) Connect reverse lamp electrical connector at transmission. (11) Connect both shifter cables (Refer to 21 TRANSMISSION/TRANSAXLE/MANUAL/GEAR SHIFT CABLE - INSTALLATION). (12) Connect the clutch slave cylinder quick disconnect connector (RHD only)(Refer to 6 - CLUTCH/ SLAVE CYLINDER - INSTALLATION). (13) Install engine harness into bracket on transmission. (14) Lower vehicle. (15) Connect fuel supply and return lines. (16) Connect A/C lines to A/C compressor. Torque to 23N·m (17 ft. lbs.) (17) Route engine wiring harnes to proper location. (18) Connect engine harness ground cables to engine block (19) Connect starter solenoid electrical connector and battery feed wire to starter. Torque to 10N·m (90 in. lbs.) (20) Connect A/C compressor, injection pump, glow plugs, and coolant temperature sensor electrical connectors. (21) Connect generator electrical connector. Torque to 9N·m (75 in. lbs.) (22) Connect the fuel injector, fuel pressure sensor, boost pressure/intake air temp sensor, cam sensor, and egr solenoid electrical connectors (Fig. 8). (23) Connect egr solenoid vacuum supply line to brake boost vacuum supply line. (24) Connect brake booster vacuum supply line. (25) Connect heater core return hose to coolant pipe. (26) Connect lower radiator hose to engine (Fig. 7). (27) Install charger air cooler inlet hose (Fig. 6). (28) Install charge air cooler outlet hose (Fig. 6). (29) Connect upper radiator hose to engine (Fig. 7). (30) Install battery shield. (31) Install coolant reserve pressure container (Refer to 7 - COOLING/ENGINE/COOLANT RECOVERY PRESS CONTAINER - INSTALLATION). (32) Install power steering reservoir and bracket (Fig. 4). (33) Raise vehicle (34) Connect oil pressure sensor, oil temperature sensor, engine speed sensor, and vehicle speed sensor electrical connector (Fig. 9). (35) Install suspension cradle in vehicle (Refer to 13 - FRAME & BUMPERS/FRAME/ENGINE CRADLE CROSSMEMBER - INSTALLATION). (36) Install both axle shaft assemblies (Refer to 3 DIFFERENTIAL & DRIVELINE/HALF SHAFT INSTALLATION). (37) Connect the power steering supply, pressure, and return lines to power steering pump (Fig. 4). (38) Install the power steering line brackets on oil pan (Fig. 4). (39) Install lower splash shield and side panels. (40) Install both front wheel and tire assemblies. (41) Lower vehicle. (42) Install air cleaner housing, MAF sensor, and air intake tube assembly (Fig. 3). (43) Refill transmission to proper level (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL/FLUID STANDARD PROCEDURE). (44) Refill engine coolant (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (45) Recharge A/C system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE) . (46) Install engine cover (Refer to 9 - ENGINE INSTALLATION) (Fig. 2). (47) Connect negative battery cable. INSTALLATION - ENGINE COVER (1) Install engine cover on engine. (2) Install the engine cover mounting bolts (Fig. 10). 9a - 8 ENGINE RG ENGINE 2.5L TURBO DIESEL (Continued) SPECIFICATIONS SPECIFICATIONS - 2.5L COMMON RAIL DIESEL ENGINE ENGINE SPECIFICATIONS DESCRIPTION SPECIFICATION Type R2516C Number of Cylinders 4 Bore 92 mm Stroke 94 mm Displacement 2499.5cc Injection Order 1-3-4-2 Compression Ratio 17.5:1 (± 0.5) Maximum Power 103kW (140 HP) @ 4000 RPM Peak Torque 320Nm (32.6 kgm) @ 2000 RPM CRANKSHAFT Front Journal Diameter Nominal 62.985-63.005 mm -0.25 62.735-62.755 mm Front Bearing Diameter DESCRIPTION SPECIFICATION -0.25 53.690-53.705 mm Connecting Rod Bearing Nominal 53.977-54.016 mm -0.25 53.727-53.766 mm Clearance Between Journal and Bearing 0.022-0.076 mm Crankshaft End Play End Play 0.080-0.280 mm Adjustment Thrust Washers Thrust Washers Available 2.31-2.36 mm 2.41-2.46 mm 2.51-2.56 mm Carrier with thrust washers installed 27.670-27.820 mm MAIN BEARING CARRIERS Internal Diameter Front 67.025-67.050 mm Center 66.670-66.690 mm Rear 85.985-86.005 mm LINERS Internal Diameter 91.997-92.015 mm Protrusion 0.01-0.06 mm Nominal 63.045-63.074 mm -0.25 62.795-62.824 mm Adjustment Shims 0.040-0.089 mm Available Shims 0.15 mm Clearance Between Journal and Bearing 0.17 mm Center Journal Diameter 0.20 mm Nominal 63.005-63.020 mm 0.23 mm -0.25 62.755-62.770 mm 0.25 mm Center Bearing Diameter CYLINDER HEAD Nominal 63.005-63.020 mm Minimum Thickness 89.95-90.05 mm -0.25 62.755-62.770 mm Gasket Thickness Clearance Between Journal and Bearing 0.008-0.051 mm 1.32 mm ± 0.08, 0 notches 1.42 mm ± 0.08, 1 notch Rear Journal Diameter Nominal 89.980-90.000 mm -0.25 89.730-99.750 mm Rear Bearing Diameter Nominal 90.045-90.065 mm -0.25 89.795-89.815 mm Clearance Between Journal and Bearing 0.045-0.080 mm Connecting Rod Journal Nominal 53.940-53.955 mm 1.52 mm ± 0.08, 2 notches CONNECTING RODS Weight (without the crankbearing) 1129-1195 grams Small End Bearing Internal Diameter 30.035-30.050 mm Large End Internal Diameter 53.977-54.016 mm ENGINE RG 9a - 9 ENGINE 2.5L TURBO DIESEL (Continued) DESCRIPTION SPECIFICATION PISTONS Skirt Diameter (measured at approximately 10 mm above the bottom of the skirt) 91.912-91.928 mm Piston Clearance 0.065-0.083 mm Top of Piston to Cylinder Head 0.69-0.83 mm Piston Potrusion SPECIFICATION Opens 65° B.B.D.C. Closes 29° A.T.D.C. Face Angle Intake 45° 25’-55° 35’ Exhaust 45° 25’-45° 35’ Head Diameter Intake 32.30-32.50 mm 0.49-0.60 Fit Gasket Exhaust 30.80-31.00 mm Number (1.32), 0 notches or holes Head Stand Down Intake 1.08-1.34 mm 0.61-0.70 Fit Gasket Exhaust 0.99-1.25 mm Number (1.42), 1 notch or hole Stem Diameter Intake 5.952-5.970 mm 0.71-0.83 Fit Gasket Exhaust 5.942-5.960 mm Number (1.52), 2 notches or holes Clearance in Guide PISTON PINS Type Full Floating Pin Diameter 29.992-29.996 mm Clearance 0.004-0.012 mm PISTON RINGS Clearance in Groove Top 0.078-0.137 mm Second 0.070-0.110 mm Oil Control 0.040-0.080 mm Fitted Gap Top 0.30-0.45 mm Second 0.30-0.45 mm Oil Control 0.25-0.50 mm CAMSHAFT Journal Diameter–Front 29.960-29.980 mm Bearing Clearance 0.03-0.08 mm Journal Diameter–Center 39.250-39.270 mm Bearing Clearance 0.03-0.08 mm Journal Diameter–Rear 39.250-39.270 mm Bearing Clearance 0.03-0.08 mm HYDRAULIC LIFTER Outside Diameter 11.994 ± 0.006 mm VALVES Intake Valve Opens 16° B.T.D.C. Closes 58° A.B.D.C. Exhaust Valve DESCRIPTION Intake 0.030-0.060 mm Exhaust 0.040-0.070 mm VALVE GUIDE Inside Diameter 6.00-6.012 mm Fitted Height Intake 14.5-15.0 mm Exhaust 16.5-17.0 mm VALVE SPRINGS Free Length 45.26 mm Fitted Length 38.00 mm Load at Fitted Length 182 ± 5-10% Kg Load at Top of Lift 395 ± 5% Kg Number of Coils 8 LUBRICATION System Pressure at 4000 RPM 4.5-5.0 bar (oil at 90-100°C) Pressure Relief Valve Opens 6.50 bar Pressure Relief Valve Spring-Free Length 51.5 mm OIL PUMP Outer Rotor End Float 0.060-0.160 mm Inner Rotor End Float 0.060-0.160 mm Outer Rotor to Body Diameter Clearance 0.130-0.240 mm Rotor Body to Drive Gear Clearance (pump not fitted) 0.90-1.50 mm 9a - 10 ENGINE RG ENGINE 2.5L TURBO DIESEL (Continued) SPECIFICATIONS - TORQUE 2.5L DIESEL TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Oil Pump Bolts 10.8 8 96 Vacuum Pump Bolts 10.8 8 96 Crankshaft Gear Bolts 10.8 8 96 Crankshaft Position Sensor Bolts 10.8 8 96 Reluctor Wheel Bolts 14.6 11 130 Rear Main Bearing Support Bolts 27.5 21 240 Oil Cooler to Engine Block Bolt 47.1 35 — Oil Cooler Mounting Stud 50 37 — Water Pump Housing Nuts 24.4 18 212 Balance Shaft Bolts 32.4 24 — Oil Jet Bolts 10.8 8 96 Oil Pan Bolts 11.8 8 96 Crankshaft Hub Bolt 304 225 — Front Engine Cover Bolts 11.8 8 96 Transmission to Engine Bolts 83.4 62 — Cylinder Head Cover / Intake Manifold Bolts 27.5 20 — Camshaft Access Plugs 80 59 — Oil Separator Bolts 10.8 8 96 Camshaft Position Sensor Bolt 10.8 8 96 Boost Pressure / Intake Air Temp. Sensor Bolts 5.4 — 48 Accessory Drive Bracket Bolts 47.1 35 — Vacuum Line Fitting Bolt 56.9 42 — Fuel Pump Nuts 27.5 21 — Fuel Line Fittings at Pump 27.5 21 — Flywheel Bolts - Refer to the Service Procedure Cylinder Head Bolts Refer to the Service Procedure Connecting Rod Bolts Refer to the Service Procedure Inner Timing Belt Cover Bolts ENGINE RG ENGINE 2.5L TURBO DIESEL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. 8mm 10.8 8 96 10mm 47.1 35 — 3mm 6 — 54 8mm 10.8 8 96 Engine Mount Bracket to Cylinder Head Bolts 47.1 35 — Outer Timing Belt Cover Bolts Intake Inlet Tube Bolts 10.1 8 89 Camshaft Sprocket Bolts 108 80 — Timing Belt Idler Pulley Bolt 47.1 35 — Timing Belt Tensioner Bolt 34.7 26 — Fuel Pump Nut 88.3 65 — Engine Lift Hook Bolts 32.4 24 — Thermostat Housing Bolts 27.5 21 — Turbocharger Oil Feed Line Fitting 24.5 18 217 Exhaust Manifold Nuts 32.4 24 — Exhaust Manifold Heatshield Bolts 27.5 21 — EGR Valve Nuts 32.4 24 — EGR Cooler to EGR Bolts 32.4 24 — Turbocharger Downpipe Nuts 32.4 24 — Turbocharger Bracket Bolts 47.1 35 — Vibration Damper to Crankshaft Hub Bolts 27.5 21 — Crankshaft Support Bolts 44.1 33 — Turbocharger to Exhaust Manifold Nuts 32.4 24 — 9a - 11 9a - 12 ENGINE RG ENGINE 2.5L TURBO DIESEL (Continued) SPECIAL TOOLS VM.1013 DIAL INDICATOR VM.1001 CYLINDER LINER PULLER VM.1005 TORQUE ANGLE GAUGE VM.1016 CYLINDER RETAINER VM.1010 CYLINDER LINER PROTRUSION TOOL ENGINE RG 9a - 13 ENGINE 2.5L TURBO DIESEL (Continued) VM.1050 CRANKSHAFT REAR SEAL INSTALLER VM.1053 EXHAUST CAMSHAFT ALIGNMENT PIN VM.1054 RELIEF VALVE REMOVER/CENTRAL CARRIER PIN REMOVER/INSTALLER VM.1051 TDC ALIGNMENT PIN VM.1052 INTAKE CAMSHAFT ALIGNMENT PIN VM.1055 CAMSHAFT/INJECTION PUMP GEAR HOLDER 9a - 14 ENGINE RG ENGINE 2.5L TURBO DIESEL (Continued) VM.1056 BALANCE SHAFT LOCKING PIN VM.1061 FRONT OIL SEAL INSTALLER VM.1062 POWER STEERING PUMP INSTALLER VM.1059 OIL PRESSURE RELIEF VALVE INSTALLER VM.1060 OIL JET REMOVER /INSTALLER VM.1063 FUEL INJECTOR REMOVER ENGINE RG 9a - 15 ENGINE 2.5L TURBO DIESEL (Continued) VM.1068 90 DEGREES AFTER TDC ALIGNMENT PIN VM.1064 POWER STEERING PUMP GEAR REMOVER VM.1069 CRANKSHAFT REM/INSTALL SLEEVE VM.1065 PISTON RING COMPRESSOR VM.1066 CYLINDER HEAD COVER ALIGNMENT PINS VM.1070 FLYWHEEL LOCKING TOOL 9a - 16 ENGINE RG ENGINE 2.5L TURBO DIESEL (Continued) VM.1072 COMPRESSION TESTER ADAPTER VM.1075 FLYWHEEL ALIGNMENT PINS VM.1073 CRANKSHAFT FRONT BEARING REMOVER/INSTALLER VM.1077 POWER STEERING BELT REMOVER VM.1078 POWER STEERING BELT INSTALLER VM.1074 TIMING BELT RETAINER ENGINE RG 9a - 17 CYLINDER HEAD STANDARD PROCEDURE STANDARD PROCEDURE - VALVE SERVICE This procedure is done with the engine cylinder head removed from the block. DISASSEMBLY (1) Remove the engine cylinder head from the cylinder block. Refer to cylinder head removal and installation in this section. (2) Use Valve Spring Compressor Tool and compress each valve spring. (3) Remove the valve locks, retainers, and springs. (4) Use an Arkansas smooth stone or a jewelers file to remove any burrs on the top of the valve stem, especially around the groove for the locks. (5) Remove the valves, and place them in a rack in the same order as removed. VALVE CLEANING (1) Clean all carbon deposits from the combustion chambers, valve ports, valve stems, valve stem guides and head. (2) Clean all grime and gasket material from the engine cylinder head machined gasket surface. INSPECTION (1) Inspect for cracks in the combustion chambers and valve ports. (2) Inspect for cracks on the exhaust seat. (3) Inspect for cracks in the gasket surface at each coolant passage. (4) Inspect valves for burned, cracked or warped heads. (5) Inspect for scuffed or bent valve stems. (6) Replace valves displaying any damage. (7) Check valve spring height (Fig. 11). VALVE REFACING (1) Use a valve refacing machine to reface the intake and exhaust valves to the specified angle. (2) After refacing, a margin of at least 4.52-4.49 mm (.178-.177 inch) must remain (Fig. 12). If the margin is less than 4.49 mm (.177 inch), the valve must be replaced. VALVE SEAT REFACING (1) Install a pilot of the correct size in the valve guide bore. Reface the valve seat to the specified angle with a good dressing stone. Remove only enough metal to provide a smooth finish. (2) Use tapered stones to obtain the specified seat width when required. Fig. 11 VALVE SPRING CHART P1 P2 P3 LOAD Kg 0.00 182-5 +10% 395±5% H1 H2 HEIGHT mm 45.26 38.00 H3 28.20 STATE FREE LENGTH VALVE CLOSED VALVE OPEN VALVE STAND DOWN Valve stand down is to maintain the adequate compression ratio. (1) Invert cylinder head. (2) Fit each valve to its respective valve guide. (3) Using a straight edge and feeler gauge, check valve head stand down: Inlet valve head stand down 1.08 to 1.34 mm (.042 to .052 ins.) and exhaust valve stand down .99 to 1.25 mm (.035 to .049 ins.). (4) If valve head stand down is not in accordance with above, discard original valves, check stand down with new valves and recut valve seat inserts to obtain correct stand down. VALVE GUIDES (1) Valve Guides height requirement. (2) Measurement A (Fig. 13): 16.50 - 17.00 mm. Measurment B : 14.50 - 15.00 mm. VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT (1) Measure and record internal diameter of valve guides. Valve guide internal diameter is 8.0 to 8.015 mm (.3149 to .3155 ins.). (2) Measure valve stems and record diameters. Intake valve stem diameter 7.94 to 7.96 mm (.3125 to 9a - 18 ENGINE RG CYLINDER HEAD (Continued) Fig. 13 VALVE GUIDE HEIGHT .3133 in). Exhaust valve stem diameter 7.92 to 7.94 mm (.3118 to .31215 in). (3) Subtract diameter of valve stem from internal diameter of its respective valve guide to obtain valve stem clearance in valve guide. Clearance of inlet valve stem in valve guide is .040 to .075 mm (.0015 to .0029 in). Clearance of exhaust valve stem in valve guide is .060 to .093 mm (.0023 to .0036 in). (4) If valve stem clearance in valve guide exceeds tolerances, new valve guides must be installed. STANDARD PROCEDURE - MEASURING PISTON PROTRUSION Fig. 12 VALVE SPECS. MEASUREMENT A B C INTAKE 7.940-7.960 8.00-8.015 1.08-1.34 D 2.2 ± 0.08 E F G H I L 1.80-2.20 2.73-3.44 41.962-41.985 42.070-42.086 7.14-7.19 3.11-3.26 EXHAUST 7.922-7.940 8.000-8.015 0.990-1.250 +0.07 2.09 20.09 1.65-2.05 2.45-3.02 35.964-35.987 36.050-36.066 7.00-7.05 3.10-3.25 (1) Use special tool VM.1010 with dial indicator special tool VM.1013 (Fig. 14). (2) Bring the piston of cylinder no. 1 exactly to top dead center. (3) Zero the dial indicator on the cylinder block mating surface. (4) Setup the dial indicator on the piston crown (above the center of the piston pin) 5mm (1/8 in.) from the edge of the piston and note the measurement. (5) Repeat the procedure with the rest of the cylinders. (6) Establish the thickness of the steel gasket by averaging the four piston potrusion readings. ENGINE RG 9a - 19 CYLINDER HEAD (Continued) (8) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). CAUTION: Before removing the cylinder head cover/ intake manifold or timing belt the engine must put at 90° after TDC. Failure to do so could result in valve and/or piston damage during reassembly. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE) Fig. 14 MEASURING PISTON PROTRUSION Measure Dimension (mm) 0.49-0.60 Cylinder Head Gasket Thickness (mm) 1.32 No Holes or Notches Piston Clearance (mm) 0.72-0.83 Measure Dimension (mm) 0.61-0.70 Cylinder Head Gasket Thickness (mm) 1.42 1 Hole or Notch Piston Clearance (mm) 0.72-0.84 Measure Dimension (mm) 0.71-0.83 Cylinder Head Gasket Thickness (mm) 1.52 2 Holes or Notches Piston Clearance (mm) 0.68-0.81 (9) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (10) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (11) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (12) Remove cylinder head cover/intake manifold (Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/ CYLINDER HEAD COVER(S) - REMOVAL). REMOVAL (1) Disconnect negative battery cable. (2) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (3) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (4) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (5) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (6) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (7) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL). Fig. 15 CYLINDER HEAD COVER/INTAKE MANIFOLD ASSEMBLY 1 - CYLINDER HEAD 2 - CYLINDER HEAD 3 - CYLINDER HEAD 4 - CYLINDER HEAD 5 - CYLINDER HEAD BOLTS(SHORT) COVER/INTAKE MANIFOLD BOLTS(LONG) COVER/INTAKE MANIFOLD COVER/INTAKE MANIFOLD GASKET COVER/INTAKE MANIFOLD 9a - 20 ENGINE RG CYLINDER HEAD (Continued) (13) Remove rocker arm and lifter assemblies from cylinder head. (14) Remove cylinder head cover/intake manifold gasket from cylinder head. (15) Disconnect glow plug and engine coolant temperture electrical connectors. (16) Remove coolant recovery pressure container (Refer to 7 - COOLING/ENGINE/COOLANT RECOVERY PRESS CONTAINER - REMOVAL). (17) Remove thermostat housing to upper radiator hose pipe (Fig. 16). (18) Remove turbocharger outlet to charge air cooler pipe (Fig. 16). (19) Remove exhaust manifold heat shield (Fig. 17). Fig. 17 EXHAUST MANIFOLD AND TURBOCHARGER Fig. 16 TURBOCHARGER AND COOLANT PIPES 1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT 2 - TURBOCHARGER OUTLET PIPE 3 - ADAPTER HOSE 4 - HEAT SHIELD 5 - HOSE CLAMPS 6 - TURBOCHARGER INLET PIPE RETAINING BOLT 7 - TURBOCHARGER INLET PIPE 8 - ADAPTER HOSE 9 - HOSE CLAMPS 10 - CLAMP 11 - EGR VALVE TO INTAKE AIR INLET PIPE 12 - CLAMP 13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE 1 - TURBOCHARGER OIL SUPPLY BANJO BOLT 2 - COPPER WASHER 3 - EXHAUST MANIFOLD GASKET 4 - COPPER WASHER 5 - EXHAUST MANIFOLD HEAT SHIELD RETAINING BOLT 6 - TURBOCHARGER 7 - ENGINE LIFT HOOK 8 - ENGINE LIFT HOOK RETAINING BOLT 9 - SPACER 10 - EXHAUST MANIFOLD RETAINING NUT 11 - TURBOCHARGER OIL RETURN HOSE 12 - HOSE CLAMPS 13 - EXHAUST MANIFOLD STUDS (20) Remove exhaust manifold retaining nuts (Fig. 17). (21) Slide exhaust manifold and turbocharger off of exhaust manifold studs (Fig. 17). (22) Remove cylinder head bolts. ENGINE RG 9a - 21 CYLINDER HEAD (Continued) (23) Remove cylinder head assembly from engine block (Fig. 18). INSTALLATION CAUTION: Piston protrusion must be measured to determine cylinder head gasket thickness if one or more cylinder liners have been replaced (Refer to 9 - ENGINE/CYLINDER HEAD - STANDARD PROCEDURE). NOTE: If cylinder liner(s) have not been removed, the same thickness head gasket that was removed can be used. (1) Clean and inspect gasket mating surfaces. (2) Position correct head gasket on engine block. (3) Place cylinder head on engine block (Fig. 18). CAUTION: New cylinder head bolts must be used. (4) Tighten cylinder head bolts following procedure below. Cylinder Head Bolt Torquing Procedure Fig. 18 CYLINDER HEAD ASSEMBLY 1 - VALVE SPRING 2 - CYLINDER HEAD BOLT 3 - GLOW PLUG 4 - COOLANT TEMPERATURE SENSOR 5 - CYLINDER HEAD ALIGNMENT DOWEL 6 - CYLINDER BLOCK 7 - CYLINDER LINER 8 - ENGINE BLOCK DECK 9 - CYLINDER HEAD GASKET 10 - CYLINDER HEAD 11 - ROCKER ARM AND LIFTER ASSEMBLY (1) Lubricate cylinder head bolts with engine oil. (2) Torque bolts to 30N·m in numerical starting with bolt #1 (Fig. 19). (3) Tighten all bolts an additional 75°, starting with bolt #4 then 5-6-7-8-9-10-1-2-3 (Fig. 19). (4) Tighten all bolts an additional 50° in numerical order starting with bolt #11 then 12-13-14-15-1617-18 (Fig. 19). (5) Without loosening any bolts tighten all bolts an additional 75° in the following seguence: 4-5-6-7-8-910-1-2-3-11-12-13-14-15-16-17-18. CLEANING Thoroughly clean the engine cylinder head and cylinder block mating surfaces. Clean the intake and exhaust manifold and engine cylinder head mating surfaces. Remove all gasket material and carbon. Check to ensure that no coolant or foreign material has fallen into the tappet bore area. Remove the carbon deposits from the combustion chambers and top of the pistons. INSPECTION Use a straightedge and feeler gauge to check the flatness of the engine cylinder head and block mating surfaces. The minimum cylinder head thickness is 89.95mm (3.541 in.). Fig. 19 CYLINDER HEAD TORQUE SEQUENCE 9a - 22 ENGINE RG CYLINDER HEAD (Continued) (5) Slide exhaust manifold and turbocharger on exhaust manifold studs (Fig. 17). (6) Install exhaust manifold retaining nuts. Torque nuts to 32.4N·m. (7) Install exhaust manifold heat shield (Fig. 17). Torque bolts to 27.5N·m. (8) Install turbocharger outlet to charge air cooler pipe (Fig. 16). (9) Install thermostat housing to upper radiator hose pipe (Fig. 16). Install retaining bolt and torque to 47.1N·m. (10) Install coolant recovery pressure container (Refer to 7 - COOLING/ENGINE/COOLANT RECOVERY PRESS CONTAINER - INSTALLATION). (11) Connect glow plug and coolant temperature sensor electrical connectors. (12) Install new cylinder head cover/intake manifold gasket. (13) Install rocker arm and lifter assemblies.Be sure to put rocker arm and lifter assemblies in same location as removed. (14) Install cylinder head cover/intake manifold (Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/ CYLINDER HEAD COVER(S) - INSTALLATION). (15) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (16) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (17) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (18) Remove crankshaft and both camshaft locking pins at this time (Refer to 9 - ENGINE/ VALVE TIMING - STANDARD PROCEDURE). (19) Install generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION). (20) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (21) Install power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (22) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (23) Install air cleaner housing assembly. (24) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (25) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (26) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (27) Connect negative battery cable. CAMSHAFT(S) DESCRIPTION The camshafts are made of gray cast iron with eight machined lobes and four bearing journals (Fig. 20). Fig. 20 CAMSHAFTS 1 - INTAKE CAMSHAFT 2 - EXHAUST CAMSHAFT OPERATION When the camshaft rotates the lobes actuate the hydraulic lifters and rocker arms, forcing downward on the rocker arms which opens the valves. REMOVAL (1) Disconnect negative battery cable. (2) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (3) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (4) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (5) Remove air cleaner housing. (6) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (7) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (8) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL). (9) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). ENGINE RG 9a - 23 CAMSHAFT(S) (Continued) CAUTION: Before removing the cylinder head cover/ intake manifold or timing belt the engine must put at 90° after TDC. Failure to do so could result in valve and/or piston damage during reassembly. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE) (10) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (11) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (12) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (13) Remove cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). (14) With cylinder head cover/intake manifold on work bench, remove plugs at rear of cylinder head cover/intake manifold. (15) Remove camshaft oil seals (Fig. 21). (16) Remove snapring and thrust washer from camshaft (Fig. 21). (17) Slide camshaft through access hole at rear of cylinder head cover/intake manifold. INSTALLATION (1) Lubricate the camshafts with Mopart Engine Oil Supplement, or equivalent. (2) Carefully install camshafts into access holes in rear of cylinder head cover/intake manifold. (3) Install thrust washer, snapring, and camshaft oil seal (Fig. 21). CHECKING CAMSHAFT ENDPLAY (1) After camshafts are properly installed in cylinder head cover check end play of camshafts with a dial indicator. The end play should be between .10 mm – .30 mm. NOTE: If the camshaft endplay is not within specification, measure thickness of the camshaft spacer. Camshaft spacer thickness should be 2.8 ± .02mm. (4) Install access hole plugs and gaskets at rear of cylinder head cover/intake manifold. Torque plugs to 80N·m. (5) Install cylinder head cover/intake manifold on engine block (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). (6) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). Fig. 21 CAMSHAFT ASSEMBLY 1 2 3 4 5 6 - INTAKE CAMSHAFT SNAPRING CAMSHAFT OIL SEAL THRUST WASHER CYLINDER HEAD COVER/INTAKE MANIFOLD EXHAUST CAMSHAFT (7) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (8) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (9) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (10) Install generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION). (11) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (12) Install power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (13) Install air cleaner housing. (14) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (15) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (16) Connect negative battery cable. 9a - 24 ENGINE CYLINDER HEAD COVER(S) DESCRIPTION The cylinder head cover is made of cast aluminum and is also the intake manifold on this engine (Fig. 22). RG (8) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (9) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL). (10) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/ RIGHT MOUNT - REMOVAL). (11) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (12) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (13) Remove inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (14) Disconnect camshaft position sensor, boost pressure/intake air temperature sensor, EGR solenoid, and fuel pressure sensor electrical connectors (Fig. 23). Fig. 22 CYLINDER HEAD COVER/INTAKE MANIFOLD REMOVAL CAUTION: Before removing the cylinder head cover/ intake manifold the engine must put at 90° after TDC. Failure to do so could result in valve and/or piston damage during reassembly. (Refer to 9 ENGINE/VALVE TIMING - STANDARD PROCEDURE) (1) Disconnect negative battery cable. (2) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (3) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (4) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (5) Rotate engine until 90° after TDC is reached. Install both camshaft locking pins and the crankshaft locking pin. (Refer to 9 - ENGINE/VALVE TIMING STANDARD PROCEDURE) (6) Remove air cleaner housing assembly. (7) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). Fig. 23 ENGINE COMPONENT LOCATIONS 1 - FUEL INJECTOR RETURN LINE 2 - FUEL INJECTOR SUPPLY LINE 3 - OIL SEPARATOR 4 - FUEL INJECTOR 5 - CAMSHAFT POSITION SENSOR 6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR 7 - EGR SOLENOID 8 - FUEL PRESSURE SENSOR 9 - CYLINDER HEAD COVER/INTAKE MANIFOL 10 - FUEL RAIL 11 - WIRING HARNESS RETAINING CLIPS ENGINE RG 9a - 25 CYLINDER HEAD COVER(S) (Continued) (15) Disconnect vacuum lines at EGR solenoid. (16) Position electrical harness out of way. (17) Remove fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR REMOVAL). (18) Remove fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - REMOVAL). (19) Remove power steering pump reservoir from bracket. (20) Remove oil dipstick tube retaining bolt at intake manifold inlet. (21) Disconnect oil separator outlet hose at separator. (22) Remove turbo inlet tube retaining bolt at intake manifold. (23) Disconnect EGR tube at intake manifold inlet tube. (24) Remove cylinder head cover/intake manifold retaining bolts (Fig. 24). (25) Lift cylinder head cover/intake manifold from cylinder head (Fig. 24). in an upright position when removed from cylinder head. (26) Remove rocker arm and lifter assemblies from cylinder head (Fig. 25). Fig. 25 CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET LOCATION 1 2 3 4 - THERMOSTAT HOUSING ROCKER ARM AND LIFTER ASSEMBLY CYLINDER HEAD COVER/INTAKE MANIFOLD CYLINDER HEAD (27) Remove cylinder head cover/intake manifold gasket from cylinder head. INSTALLATION (1) Clean and inspect sealing surfaces. (2) Install new gasket on cylinder head. NOTE: Apply a small amount of grease on each valve stem. This will help hold the rocker arm in position during the cylinder head cover installation. Fig. 24 CYLINDER HEAD COVER/INTAKE MANIFOLD ASSEMBLY 1 - CYLINDER HEAD 2 - CYLINDER HEAD 3 - CYLINDER HEAD 4 - CYLINDER HEAD 5 - CYLINDER HEAD BOLTS(SHORT) COVER/INTAKE MANIFOLD BOLTS(LONG) COVER/INTAKE MANIFOLD COVER/INTAKE MANIFOLD GASKET COVER/INTAKE MANIFOLD NOTE: When removing rocker arm and lifter assemblies, be sure to keep them in order as they were removed from the cylinder head. Always keep lifters (3) Install rocker arm and lifter assemblies in cylinder head (Fig. 25).Be sure to put rocker arm and lifter assemblies in same location as removed. (4) Install cylinder head cover/intake manifold alignment studs in cylinder head (Fig. 26). (5) Install cylinder head cover/intake manifold over alignment stud. 9a - 26 ENGINE RG CYLINDER HEAD COVER(S) (Continued) Fig. 26 CYLINDER HEAD COVER/INTAKE MANIFOLD ALIGNMENT STUDS VM.1066 1 - CYLINDER HEAD COVER/INTAKE MANIFOLD ALIGNMENT STUDS VM.1066 2 - CYLINDER HEAD NOTE: Be sure to lubricate cylinder head cover/intake manifold retaining bolts with engine oil before assembly. If new bolts are being installed, DO NOT lubricate before assembly. (6) Install two cylinder head cover/intake manifold retaining bolts and tighten finger tight. (7) Remove alignment studs and install remaining retaining bolts (Fig. 24). Tighten retaining bolts finger tight. (8) Torque cylinder head cover/intake manifold retaining bolts following procedure below. CYLINDER HEAD COVER/INTAKE MANIFOLD TIGHTENING PROCEDURE (1) Coat all bolts being reused with clean engine oil. (2) Install the M8x35 bolts into holes 1,2,3,4,5, and 12. Install the M8x85 bolts into holes 6,7,8,9,10,11,13,14,15, and 16. Tighten all bolt hand tight. (3) Alternate between bolts #11 and #16 to seat cylinder head cover/intake manifold on cylinder head (Fig. 27). Torque bolts to 7 N·m. (4) Torque all cylinder head cover/intake manifold retaining bolts to 25 N·m in numerical order starting with #1 and ending with #16 (Fig. 27). Fig. 27 CYLINDER HEAD COVER/INTAKE MANIFOLD TIGHTENING SEQUENCE (9) Connect EGR tube at intake manifold inlet tube. Torque clamp to 10.8 N·m. (10) Install turbo inlet tube retaining bolt at intake manifold. Torque bolt to 27.5 N·m. (11) Connect oil separator outlet hose at separator. (12) Install oil dipstick tube retaining bolt at intake manifold inlet. Torque bolt to 10 N·m. (13) Install power steering pump reservoir in bracket. (14) Install fuel rail (Refer to 14 - FUEL SYSTEM/ FUEL DELIVERY/FUEL RAIL - INSTALLATION). (15) Install fuel injectors and fuel injector supply lines (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION). (16) Connect vacuum lines at EGR solenoid. (17) Clip wiring harness retainers on studs on fuel rail (Fig. 23). (18) Connect camshaft position sensor, boost pressure/intake air temperature sensor, EGR solenoid, and fuel pressure sensor electrical connectors (Fig. 23). (19) Install inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (20) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (21) Install outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). ENGINE RG 9a - 27 CYLINDER HEAD COVER(S) (Continued) (22) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (23) Install generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION). (24) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (25) Install power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (26) Install air cleaner housing assembly. (27) Remove crankshaft and both camshaft locking pins (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE). (28) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (29) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (30) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (31) Connect negative battery cable. CAMSHAFT OIL SEAL(S) REMOVAL (1) Disconnect negative battery cable. (2) Remove air cleaner housing assembly. (3) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). (4) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). WARNING: Before removing the timing belt the engine must put at 90° after TDC. Failure to do so could result in valve and/or piston damage during reassembly. (Refer to 9 - ENGINE/VALVE TIMING STANDARD PROCEDURE) (5) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (6) Using VM.1055, remove both camshaft gears (Fig. 28). (7) Remove both camshaft oil seals. INSTALLATION (1) Install new camshaft oil seal using VM.1057. (2) Install camshaft sprockets and tighten retaining bolts finger tight. (3) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . Fig. 28 CAMSHAFT GEAR REMOVAL/INSTALLATION 1 2 3 4 5 - TIMING BELT INNER COVER CAMSHAFT SPROCKET IDLER PULLEYS CAMSHAFT SPROCKET VM.1055 (4) Torque camshaft sprockets to 108 N·m using VM.1055 (Fig. 28). (5) Install outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (6) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (7) Install air cleaner housing assembly. (8) Connect negative battery cable. ROCKER ARMS DESCRIPTION The rocker arms are made of stamped steel (Fig. 29). OPERATION The rocker arms are used as a link between the camshaft and valves. As the camshaft rotates the lobes of the camshafts apply downward pressure on the rocker arms. This pressure is then transmitted to the valves which causes the valves to open. REMOVAL (1) Disconnect negative battery cable. 9a - 28 ENGINE RG ROCKER ARMS (Continued) (9) Remove rocker arm from lifter (Fig. 30). Fig. 30 ROCKER ARM ASSEMBLY Fig. 29 CYLINDER HEAD ASSEMBLY 1 - VALVE SPRING 2 - CYLINDER HEAD BOLT 3 - GLOW PLUG 4 - COOLANT TEMPERATURE SENSOR 5 - CYLINDER HEAD ALIGNMENT DOWEL 6 - CYLINDER BLOCK 7 - CYLINDER LINER 8 - ENGINE BLOCK DECK 9 - CYLINDER HEAD GASKET 10 - CYLINDER HEAD 11 - ROCKER ARM AND LIFTER ASSEMBLY (2) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (3) Remove air cleaner housing assembly. (4) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). (5) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (6) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (7) Remove inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (8) Remove cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). 1 2 3 4 5 - ROCKER ARM ASSEMBLY CYLINDER HEAD COVER/INTAKE MANIFOLD HYDRAULIC LIFTER CYLINDER HEAD VALVE INSTALLATION (1) Clean and inspect gasket sealing surfaces. (2) Install new gasket on cylinder head. (3) Lubricate lifter ball end of lifter(s), valve(s), and rocker arm roller(s) with Mopart Engine Oil Supplement or equivlalent. (4) Connect rocker arm(s) to lifter and reposition on valve(s) (Fig. 30). (5) Install cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). (6) Install inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (7) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (8) Install outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (9) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (10) Install air cleaner housing assembly. ENGINE RG 9a - 29 ROCKER ARMS (Continued) (11) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (12) Connect negative battery cable. HYDRAULIC LIFTERS DESCRIPTION Valve lash is controlled by hydraulic tappets located inside the cylinder head, in tappet bores below the camshafts (Fig. 31). (3) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (4) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). (5) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). CAUTION: Before removing the cylinder head cover/ intake manifold or the timing belt the engine must put at 90° after TDC. Failure to do so could result in valve and/or piston damage during reassembly. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE) (6) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (7) Remove inner timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (8) Remove cylinder head cover/intake manifold (Fig. 32)(Refer to 9 - ENGINE/CYLINDER HEAD/ CYLINDER HEAD COVER(S) - REMOVAL). Fig. 31 CYLINDER HEAD ASSEMBLY 1 - VALVE SPRING 2 - CYLINDER HEAD BOLT 3 - GLOW PLUG 4 - COOLANT TEMPERATURE SENSOR 5 - CYLINDER HEAD ALIGNMENT DOWEL 6 - CYLINDER BLOCK 7 - CYLINDER LINER 8 - ENGINE BLOCK DECK 9 - CYLINDER HEAD GASKET 10 - CYLINDER HEAD 11 - ROCKER ARM AND LIFTER ASSEMBLY REMOVAL (1) Disconnect negative battery cable. (2) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). Fig. 32 CYLINDER HEAD COVER/INTAKE MANIFOLD 1 - CYLINDER HEAD 2 - CYLINDER HEAD 3 - CYLINDER HEAD 4 - CYLINDER HEAD 5 - CYLINDER HEAD BOLTS(SHORT) COVER/INTAKE MANIFOLD BOLTS(LONG) COVER/INTAKE MANIFOLD COVER/INTAKE MANIFOLD GASKET COVER/INTAKE MANIFOLD 9a - 30 ENGINE RG HYDRAULIC LIFTERS (Continued) (9) Remove rocker arm and lifter assemblies from lifter bores. CRANKSHAFT DESCRIPTION INSPECTION Clean each lifter assembly in cleaning solvent to remove all varnish and sludge deposits. Inspect for indications of scuffing on the side and base of each lifter body. The crankshaft is a forged steel type design with five main bearing journals. The crankshaft is located at the bottom of the engine block and is held in place with three main bearing supports (Fig. 34). INSTALLATION (1) Install rocker arm and lifter assemblies in lifter bores. (2) Install cylinder head cover/intake manifold (Fig. 32) (Refer to 9 - ENGINE/CYLINDER HEAD/ CYLINDER HEAD COVER(S) - INSTALLATION). (3) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (4) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (5) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (6) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (7) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (8) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (9) Connect negative battery cable. ENGINE BLOCK DESCRIPTION The 2.5L CRD Diesel engine uses a cast iron engine block with wet cast iron cylinder liners (Fig. 33). Fig. 34 CRANKSHAFT ASSEMBLY 1 2 3 4 5 6 7 - CRANKSHAFT SUPPORT HALVE MAIN BEARING HALVE CRANKSHAFT MAIN BEARING HALVE CRANKSHAFT SUPPORT HALVE MAIN BEARING SUPPORT BOLTS WASHERS OPERATION The crankshaft transfers force generated by combustion within the cylinder bores to the flywheel or flexplate. Fig. 33 ENGINE BLOCK ENGINE RG 9a - 31 CRANKSHAFT (Continued) STANDARD PROCEDURE - CHECKING CRANKSHAFT END PLAY (1) Mount a dial indicator to a stationary point at rear of engine. Locate the probe perpendicular against the flywheel (Fig. 35). (2) Move the crankshaft all the way to the front of its travel. (3) Zero the dial indicator. (4) Move the crankshaft all the way to the rear and read dial indicator. For crankshaft end play clearances (Refer to 9 - ENGINE - SPECIFICATIONS). REMOVAL (1) Remove engine from vehicle (Refer to 9 ENGINE - REMOVAL). (2) Mount engine on an engine stand. (3) Drain engine oil and remove oil filter. (4) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (5) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (6) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (7) Remove cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). (8) Remove cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL). (9) Remove flywheel. (10) Remove rear main bearing support/adapter plate retaining bolts and remove adapter plate (Fig. 36). Fig. 35 CHECKING CRANKSHAFT END PLAY 1 - DIAL INDICATOR 2 - ADAPTER PLATE 3 - REAR MAIN BEARING SUPPORT 4 - SEALING RING 5 - SEALING RING 6 - ALIGNMENT PIN 7 - CRANKSHAFT 8 - RELUCTOR WHEEL 9 - RELUCTOR WHEEL RETAINING BOLT 10 - REAR MAIN BEARING SUPPORT RETAINING BOLTS 11 - FLYWHEEL 12 - FLYWHEEL BOLTS Fig. 36 REAR MAIN BEARING SUPPORT 1 2 3 4 - ADAPTER PLATE - REAR MAIN BEARING SUPPORT - CRANKSHAFT - REAR MAIN BEARING SUPPORT RETAINING BOLTS 9a - 32 ENGINE RG CRANKSHAFT (Continued) (11) Remove rear main bearing support by threading two retaining bolts in holes provided. Tighten bolts equally to push main bearing support out of block (Fig. 37). Fig. 38 CRANKSHAFT SLEEVE VM.1069 1 - CRANKSHAFT SLEEVE VM.1069 2 - ENGINE BLOCK Fig. 37 REAR MAIN BEARING SUPPORT REMOVAL 1 - BOLTS 2 - REAR MAIN BEARING SUPPORT 3 - CRANKSHAFT (12) Remove front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER REMOVAL). (13) Remove crankshaft sprocket. (14) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (15) Remove oil pump pickup tube (Refer to 9 ENGINE/LUBRICATION/OIL PUMP - REMOVAL). (16) Remove balance shaft assembly (Refer to 9 ENGINE/VALVE TIMING/BALANCE SHAFT REMOVAL). (17) Remove oil jets (Refer to 9 - ENGINE/LUBRICATION/OIL JET - REMOVAL). (18) Remove piston and connecting rod assemblies (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - REMOVAL). (19) Slide special tool VM.1069 on crankshaft (Fig. 38). (20) Using special tool VM.1054, remove crankshaft support retainers (Fig. 39). (21) Slide crankshaft out rear of engine block. INSTALLATION NOTE: Before installing crankshaft in engine block, be sure the notches in the crankshaft supports are facing towards the front of the engine. Fig. 39 CRANKSHAFT SUPPORT RETAINERS/ BALANCE SHAFT OIL FEED 1 - CRANKSHAFT SUPPORT RETAINERS/BALANCE SHAFT OIL FEED 2 - ENGINE BLOCK (1) Install crankshaft in engine block. Be sure to align oil holes in crankshaft supports and engine block. (2) Install crankshaft support retainers (Fig. 39). (3) Remove special tool VM.1069 from crankshaft (Fig. 38). (4) Install crankshaft sprocket. ENGINE RG CRANKSHAFT (Continued) (5) Install front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER INSTALLATION). (6) Install rear main bearing support in engine block. Be sure to align oil hole in rear main bearing support with hole in block. (7) Install adapter plate and retaining bolts (Fig. 36). Torque bolts to 27.5N·m. (8) Install flywheel. (9) Install piston and connecting rod assemblies (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - INSTALLATION). (10) Install oil jets (Refer to 9 - ENGINE/LUBRICATION/OIL JET - INSTALLATION). (11) Install balance shaft assembly (Refer to 9 ENGINE/VALVE TIMING/BALANCE SHAFT INSTALLATION). (12) Install oil pump pickup tube (Refer to 9 ENGINE/LUBRICATION/OIL PUMP - INSTALLATION). (13) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (14) Install cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - INSTALLATION). (15) Install cylinder head cover/intake manifold (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). (16) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (17) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (18) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (19) Install engine in vehicle. (20) Fill engine oil with proper oil to correct level. Fig. 40 CYLINDER LINER REMOVER CYLINDER LINERS DESCRIPTION The cylinder wall liner used on this engine is of the wet design. O-rings are used to seal the liner to the engine block. REMOVAL (1) Remove engine from vehicle. (2) With engine completely disassembled, use special tool VM.1001 to remove liner assembly (Fig. 40). (3) Tighten bolt on VM.1001 to remove liner from block (Fig. 41). (4) Remove shims from cylinder liner or cylinder block recess. Keep shims with each cylinder liner. Fig. 41 CYLINDER LINER REMOVAL 1 - SPECIAL TOOL VM.1001 2 - CYLINDER LINER 3 - ENGINE BLOCK 9a - 33 9a - 34 ENGINE RG CYLINDER LINERS (Continued) INSPECTION The cylinder walls should be checked for out-ofround and taper with a dial bore gauge. The cylinder bore out-of-round is 0.100 mm (.0039 in.) maximum and cylinder bore taper is 0.100 mm (.0039 in.) maximum. If the cylinder walls are badly scuffed or scored, new liners should be installed and honed, and new pistons and rings fitted. Measure the cylinder bore at three levels in directions A and B (Fig. 42). Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from the bottom bore. Fig. 43 LINER INSTALLATION Fig. 42 LINER INSPECTION INSTALLATION (1) Carefully clean liner and engine block, and degrease the engine block where it comes into contact with the liners. Install the liners in the engine block as shown, rotating them back and forth by 45° in order to guarantee correct positioning (Fig. 43). (2) Measure the liner recess relative to block deck with a dial indicator mounted on a special tool VM-1010 A. All the measurements must be taken on high pressure pump side of engine block.. Zero dial gauge on block deck. (3) Move dial gauge to cylinder liner record reading on dial gauge. (4) Remove liner and special tool. (5) Then select the correct shim thickness to give proper protrusion (0.01 - 0.06 mm). (6) Fit the shim and the O-rings onto the liner. (7) Lubricate the lower liner location in the block. (8) Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat. Lock the liners in position using special tool (VM.1076) and bolts (Fig. 44). Clean the residual LOCTITE on the upper surface of the block deck. (9) Recheck the liner protrusion. It should be 0.01 - 0.06 mm. (10) Reassemble engine. (11) Install engine in vehicle. 1 2 3 4 5 - CYLINDER LINER SHIMS O-RINGS BLOCK LEDGE ENGINE BLOCK Fig. 44 LINER CLAMP LOCATION 1 - ENGINE BLOCK 2 - LINER RETAINER VM.1076 3 - CYLINDER LINER ENGINE RG 9a - 35 INTERNAL VACUUM PUMP DESCRIPTION The diesel engine uses a internal vacuum pump. This vacuum pump is mounted in the front of the engine block under the engine front cover (Fig. 45). The vacuum pump is driven by a sprocket on the crankshaft. Fig. 45 VACUUM PUMP REMOVAL (1) Disconnect negative battery cable. (2) Remove air cleaner housing. (3) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (4) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (5) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). (6) Remove vibration damper/crankshaft pulley (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL). (7) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (8) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (9) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). NOTE: Crankshaft hub has LHD thread. (10) Remove crankshaft hub. (11) Remove front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER REMOVAL). (12) Remove crankshaft sprocket (Fig. 46). (13) Remove vacuum pump (Fig. 46). Fig. 46 OIL PUMP AND VACUUM PUMP 1 2 3 4 5 - VACUUM PUMP CRANKSHAFT SPROCKET OIL PUMP ENGINE BLOCK CRANKSHAFT INSTALLATION (1) Lubricate vacuum pump blades and install in vacuum pump body as shown (Fig. 47). (2) Install vacuum pump in engine block (Fig. 46). Torque bolts to 10.8N·m. (3) Install crankshaft sprocket (Fig. 46). Torque bolts to 10.8N·m. (4) Install front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER INSTALLATION). (5) Install front crankshaft hub. Torque bolt to 304N·m. (6) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (7) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (8) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (9) Install vibration damper/crankshaft pulley. 9a - 36 ENGINE RG INTERNAL VACUUM PUMP (Continued) Fig. 47 VACUUM PUMP COMPONENTS 1 - VACUUM PUMP BODY 2 - VACUUM PUMP BLADE TAPERED EDGE 3 - VACUUM PUMP BLADE (10) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (11) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (12) Install power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (13) Install air cleaner housing. (14) Connect negative battery cable. - PISTON & CONNECTING ROD DESCRIPTION The pistons are of a free floating design. Oil jets in the engine block lubricate and cool the piston and pin assembly. The connecting rods have a pressed in place wrist pin bushing which is lubricated by the oil jets (Fig. 48). STANDARD PROCEDURE - PISTON RING FITTING (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore (Fig. 49). Check gap with feeler gauge. Top compression ring gap .30 to .45mm (.0118 to .0177 in.). Second compression ring gap .30 to .45mm Fig. 48 PISTON AND CONNECTING ROD ASSEMBLY 1 2 3 4 5 6 7 8 - PISTON PIN PISTON SNAP RING CONNECTING CONNECTING CONNECTING CONNECTING SNAP RING ROD ALIGNMENT NUMBERS ROD BOLT ROD BEARING ROD (.0118 to .0177 in.). Oil control ring gap .25 to .50mm (.0098 to .0196 in.). (2) If ring gaps exceed dimension given, new rings or cylinder liners must be fitted. Keep piston rings in piston sets. (3) Check piston ring to groove clearance (Fig. 50). Top compression ring gap .080 to .130mm (.0031 to .0051 in.). Second compression ring gap .070 to .110mm (.0027 to .0043 in.). Oil control ring gap .040 to .080mm (.0015 to .0031 in.). REMOVAL (1) Disconnect negative battery cable. (2) Remove cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL). ENGINE RG 9a - 37 PISTON & CONNECTING ROD (Continued) NOTE: Be careful not to nick or scratch crankshaft journals (9) After removal, install bearing cap on the mating rod and mark pistons with matching cylinder number when removed from engine block. PISTON PIN - REMOVAL (1) Secure connecting rods in a soft jawed vice. (2) Remove 2 snap rings securing piston pin (Fig. 51). (3) Push piston pin out of piston and connecting rod (Fig. 51). Fig. 49 RING END GAP MEASUREMENT 1 - FEELER GAUGE Fig. 50 PISTON RING TO GROOVE CLEARANCE (3) Raise vehicle on hoist. (4) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (5) Remove oil pump pickup tube.(Refer to 9 ENGINE/LUBRICATION/OIL PUMP - REMOVAL) (6) Remove balance shaft assembly (Refer to 9 ENGINE/VALVE TIMING/BALANCE SHAFT REMOVAL). (7) Remove top ridge of cylinder bores with a ridge reamer before removing pistons from cylinder block. Be sure to keep top of pistons covered during this operation. (8) Piston and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. Fig. 51 PISTON AND CONNECTING ROD ASSEMBLY 1 2 3 4 5 6 7 8 - PISTON PIN PISTON SNAP RING CONNECTING CONNECTING CONNECTING CONNECTING SNAP RING ROD ALIGNMENT NUMBERS ROD BOLT ROD BEARING ROD 9a - 38 ENGINE RG PISTON & CONNECTING ROD (Continued) PISTON RING - REMOVAL (1) ID mark on face of top and second piston rings must point toward piston crown. (2) Using a suitable ring expander, remove top and second piston rings (Fig. 52). (4) Check and record internal diameter of crank end of connecting rod. NOTE: When changing connecting rods, all four must have the same weight and be stamped with the same number. Replacement connecting rods will only be supplied in sets of four. Connecting rods are supplied in sets of four since they all must be of the same weight category. Max allowable weight difference is 5 gr. NOTE: On one side of the big end of the con-rod there is a two-digit number which refers to the weight category. On the other side of the big end there is a four digit number on both the rod and the cap. These numbers must both face the injection pump side of the block (Fig. 53). Lightly heat the piston in oven. Insert piston pin in position and secure it with provided snap rings. Fig. 52 PISTON RINGS - REMOVAL/INSTALLATION (3) Remove upper oil ring side rail, lower oil ring side rail and then the oil expander from piston. (4) Carefully clean carbon from piston crowns, skirts and ring grooves ensuring the 4 oil holes in the oil control ring groove are clear. INSPECTION PISTONS (1) Piston Diameter: Size: 91.912-91.928mm (3.6185-3.6192 in.) Maximum wear limit .05mm (.0019 in.). (2) Check piston pin bores in piston for roundness. Make 3 checks at 120° intervals. Maximum out of roundness .05mm (.0019in.). (3) The piston diameter should be measured approximately 15 mm (.590 in.) up from the base. (4) Skirt wear should not exceed 0.1 mm (.00039 in.). (5) The clearance between the cylinder liner and piston should not exceed 0.065-0.083 mm (.0025-.0032 in.). (6) Make sure the weight of the pistons does not differ by more than 5 g. CONNECTING RODS (1) Assemble bearing shells and bearing caps to their respective connecting rods ensuring that the serrations on the cap and reference marks are aligned. (2) Tighten connecting cap bolts to 29 N·m (21 ft. lbs.) plus 60°. (3) Without loosening connecting rod bolts, tighten all bolts to 88N·m. Fig. 53 CONNECTING ROD IDENTIFICATION 1 - SMALL END OF CONNECTING ROD 2 - 2 DIGIT NUMBER LOCATION 3 - 4 DIGIT NUMBER LOCATION The Four digit numbers marked on con rod big end and rod cap must be on the same side as the injection pump (Fig. 53). After having coated threads with Molyguard, tighten con rod bolts to 29 N·m (21 ft. lbs.) plus 60°. PISTON PINS (1) Measure the diameter of piston pin in the center and both ends. (2) Piston pin diameter is 29.992 to 29.996mm (1.1807 to 1.1809 in.). ENGINE RG 9a - 39 PISTON & CONNECTING ROD (Continued) INSTALLATION PISTON PIN INSTALLATION (1) Secure connecting rod in soft jawed vice. (2) Lubricate piston pin and piston with clean engine oil. (3) Position piston on connecting rod (Fig. 54). (6) Remove connecting rod from vice. PISTON RINGS - INSTALLATION (1) Install rings on the pistons using a suitable ring expander (Fig. 55). CAUTION: Ensure arrow on piston crown and the bearing cap numbers on the connecting rod are on the opposite side. (4) Install piston pin (Fig. 54). (5) Install clips in piston to retain piston pin (Fig. 54). Fig. 55 PISTON RINGS-INSTALLATION (2) Top compression ring is tapered and chromium plated. The second ring is of the scraper type and must be installed with scraping edge facing bottom of the piston. The third is an oil control ring. Ring gaps must be positioned, before inserting piston into the liners, as follows. (3) Top ring gap must be positioned at the #3 position (looking at the piston crown from above) (Fig. 56). (4) Second piston ring gap should be positioned at the #1 position (Fig. 56). (5) Oil control ring gap should be positioned at the #2 position (Fig. 56). Fig. 54 PISTON AND CONNECTING ROD ASSEMBLY 1 2 3 4 5 6 7 8 - PISTON PIN PISTON SNAP RING CONNECTING CONNECTING CONNECTING CONNECTING SNAP RING Fig. 56 PISTON RING GAP LOCATION ROD ALIGNMENT NUMBERS ROD BOLT ROD BEARING ROD 3 - TOP COMPRESSION RING GAP POSITION 1 - SECOND COMPRESSION RING GAP POSITION 2 - OIL CONTROL RING GAP POSITION (6) When assembling pistons check that components are installed in the same position as before dis- 9a - 40 ENGINE RG PISTON & CONNECTING ROD (Continued) assembly, determined by the numbers stamped on the crown of individual pistons. Engine cylinders are numbered starting from gear train end of the engine. Face arrow on top of piston toward front of engine. Therefore, the numbers stamped on connecting rod big end should face toward the injection pump side of engine. To insert piston into cylinder use a ring compressor (VM.1065) as shown in (Fig. 57). (5) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. (6) Install connecting rod caps (Fig. 58). Install rod bolts and tighten to 30N·m (22 ft.lb.) plus 60°. Then torque to 88N·m (65 ft.lb). INSTALLATION (1) Before installing pistons, and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 56). (2) Before installing the ring compressor, make sure the oil ring expander ends are butted together. (3) Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston and tighten (Fig. 57). Ensure position of rings does not change during this operation. NOTE: Be sure arrow on top of piston faces towards front of engine. NOTE: Be careful not to nick crankshaft journals. (4) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. Fig. 58 PISTON AND CONNECTING ROD INSTALLATION 1 2 3 4 - PISTON AND CONNECTING ROD ASSEMBLY FOUR DIGIT NUMBER CONNECTING ROD BOLT FOUR DIGIT NUMBER (7) Install cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - INSTALLATION). (8) Install balance shaft assembly (Refer to 9 ENGINE/VALVE TIMING/BALANCE SHAFT INSTALLATION). (9) Install oil pump pickup tube (Refer to 9 ENGINE/LUBRICATION/OIL PUMP - INSTALLATION). (10) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (11) Connect negative battery cable. Fig. 57 PISTON INSTALLATION USING VM.1065 ENGINE RG CRANKSHAFT OIL SEAL FRONT REMOVAL (1) Disconnect negative battery cable. (2) Remove air cleaner housing. (3) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). (4) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (5) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (6) Remove vibration damper/crankshaft pulley (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL). (7) Remove outer timing belt cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (8) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (9) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). NOTE: Crankshaft hub retaining bolt has LHD thread. Fig. 59 ENGINE COVER - FRONT 1 2 3 4 5 6 - CRANKSHAFT HUB RETAINING BOLT FRONT ENGINE COVER RETAINING BOLTS ENGINE BLOCK FRONT ENGINE COVER ALIGNMENT DOWELS FRONT ENGINE COVER CRANKSHAFT HUB (10) Remove crankshaft hub. (11) Remove front engine cover (Fig. 59) (Refer to 9 - ENGINE/ENGINE BLOCK/ENGINE COVER REMOVAL). (12) With cover on work bench, pry out old seal. INSTALLATION (1) Clean engine block and front engine cover sealing surfaces. (2) Install crankshaft oil seal on VM.1061 (Fig. 60). (3) Place sleeve for VM.1061 on workbench as shown (Fig. 60). Fig. 60 VM.1061 PLACEMENT 1 2 3 4 - VM.1061 FRONT ENGINE COVER WORK BENCH SLEEVE FROM VM.1061 9a - 41 9a - 42 ENGINE RG CRANKSHAFT OIL SEAL - FRONT (Continued) (4) Using hammer, install new seal into front engine cover (Fig. 61). VIBRATION DAMPER REMOVAL (1) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (2) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (3) Remove vibration damper retaining bolts and damper (Fig. 62). Fig. 61 CRANKSHAFT OIL SEAL INSTALLATION WITH VM.1061 1 - VM.1061 2 - FRONT ENGINE COVER 3 - WORK BENCH (5) Install front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER INSTALLATION). (6) Install crankshaft hub and retaining bolt. Torque bolt to 304N·m. (7) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (8) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (9) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (10) Install vibration damper/crankshaft pulley (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). (11) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (12) Install power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (13) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (14) Install air cleaner housing. (15) Connect negative battery cable. Fig. 62 VIBRATION DAMPER 1 - BELT TENSIONER RETAINING BOLT 2 - BELT TENSIONER 3 - IDLER PULLEY 4 - VIBRATION DAMPER/CRANKSHAFT PULLEY 5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING BOLTS INSTALLATION (1) Install vibration damper and retaining bolts (Fig. 62). Torque bolts to 27.5N·m. (2) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (3) Install power steering belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). ENGINE RG 9a - 43 ENGINE COVER - FRONT DESCRIPTION The front engine cover on this engine is a stamped steel cover which covers the oil pump and vacuum pump. REMOVAL (1) Disconnect negative battery cable. (2) Remove air cleaner housing. (3) Support engine and remove right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). (4) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (5) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (6) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL). (7) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). CAUTION: Before removing the cylinder head cover/ intake manifold or timing belt the engine must put at 90° after TDC. Failure to do so could result in valve and/or piston damage during reassembly. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE) (8) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (9) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). NOTE: Crankshaft hub has LHD thread. (10) Remove crankshaft hub. (11) Remove front engine cover (Fig. 63). INSTALLATION (1) Clean engine block and front engine cover sealing surfaces. (2) Apply a continous 3mm bead of Silicone Sealer to cover, install within 10 minutes (Fig. 63). Torque bolts to 11.8N·m. (3) Install crankshaft hub (Fig. 63). Torque bolt to 304N·m. (4) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). Fig. 63 ENGINE COVER - FRONT 1 2 3 4 5 6 - CRANKSHAFT HUB RETAINING BOLT FRONT ENGINE COVER RETAINING BOLTS ENGINE BLOCK FRONT ENGINE COVER ALIGNMENT DOWELS FRONT ENGINE COVER CRANKSHAFT HUB (5) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (6) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (7) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). (8) Install right engine mount (Refer to 9 ENGINE/ENGINE MOUNTING/RIGHT MOUNT INSTALLATION). (9) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (10) Install power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (11) Install air cleaner housing. (12) Connect negative battery cable. 9a - 44 ENGINE CRANKSHAFT MAIN BEARINGS RG CRANKSHAFT FRONT MAIN BEARING (1) Using special tool VM.1073 push front main bearing out of front of engine block (Fig. 65). REMOVAL The engine must be removed from vehicle and completely disassembled to replace the front main bearing. CRANKSHAFT MAIN BEARINGS (1) With crankshaft assembly removed from engine. (2) Remove crankshaft supports from crankshaft and remove bearing halves from supports (Fig. 64). Fig. 65 FRONT MAIN BEARING REMOVAL 1 - VM.1073 2 - FRONT CRANKSHAFT MAIN BEARING 3 - ENGINE BLOCK Fig. 64 CRANKSHAFT ASSEMBLY 1 2 3 4 5 6 7 - CRANKSHAFT SUPPORT HALVE MAIN BEARING HALVE CRANKSHAFT MAIN BEARING HALVE CRANKSHAFT SUPPORT HALVE MAIN BEARING SUPPORT BOLTS WASHERS ENGINE RG 9a - 45 CRANKSHAFT MAIN BEARINGS (Continued) INSTALLATION CRANKSHAFT MAIN BEARINGS (1) Install bearing halves in crankshaft supports. (2) Lubricate crankshaft and main bearings with clean engine oil. (3) Install crankshaft supports on crankshaft (Fig. 66). Torque bolts to 44.1N·m. Fig. 67 FRONT MAIN BEARING INSTALLATION 1 - FRONT CRANKSHAFT MAIN BEARING 2 - ENGINE BLOCK 3 - SPECIAL TOOL VM.1073 Fig. 66 CRANKSHAFT ASSEMBLY 1 2 3 4 5 6 7 - CRANKSHAFT SUPPORT HALVE MAIN BEARING HALVE CRANKSHAFT MAIN BEARING HALVE CRANKSHAFT SUPPORT HALVE MAIN BEARING SUPPORT BOLTS WASHERS FRONT CRANKSHAFT MAIN BEARING (1) Using special tool VM.1073, push front crankshaft main bearing in engine block (Fig. 67). (2) Be sure oil hole in bearing lines up with oil gallery in engine block (Fig. 68). (3) Reassemble engine and install in vehicle. Fig. 68 FRONT MAIN BEARING ALIGNMENT 1 - ENGINE BLOCK 2 - OIL HOLE IN BEARING 3 - FRONT CRANKSHAFT MAIN BEARING 9a - 46 ENGINE RG CRANKSHAFT OIL SEAL REAR REMOVAL This must be done with either the engine or transmission removed from vehicle. (1) Remove flywheel assembly. (2) Pry out old crankshaft oil seal. INSTALLATION (1) Using special tool VM.1050, install rear crankshaft oil seal in rear main bearing support (Fig. 69). Fig. 70 OIL PAN AND PRESSURE RELIEF VALVE Fig. 69 REAR CRANKSHAFT OIL SEAL INSTALLATION USING VM.1050 1 2 3 4 - SPECIAL TOOL VM.1050 REAR MAIN BEARING SUPPORT OIL PAN ENGINE TO TRANSMISSION ADAPTER PLATE (2) Install engine or tranmission in vehicle. OIL PAN REMOVAL (1) (2) (3) (4) (Fig. Disconnect negative battery cable. Raise vehicle on hoist. Drain engine oil from engine. Remove all oil pan retaining bolts and oil pan 70). 1 2 3 4 5 6 7 8 - OIL PAN RETAINING BOLTS POWER STEERING LINE BRACKETS OIL PAN GASKET OIL PRESSURE SENSOR ENGINE BLOCK OIL PRESSURE RELIEF VALVE OIL PAN RETAINING BOLTS OIL PAN INSTALLATION (1) Clean oil pan and sealing surfaces. Inspect oil pan and engine block. (2) Install oil pan, gasket, and retaining bolts (Fig. 70). (3) Be sure power steering line brackets are in proper location (Fig. 70). (4) Torque oil pan bolts to 11.8N·m. (5) Lower vehicle. (6) Refill engine oil to proper level. (7) Connect negative battery cable. ENGINE RG OIL PUMP REMOVAL REMOVAL (1) Disconnect negative battery cable. (2) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (3) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (4) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (5) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). (6) Remove timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (7) Remove front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER REMOVAL). (8) Remove crankshaft sprocket (Fig. 71). (9) Remove oil pump retaining bolts and remove pump from engine block (Fig. 71). 9a - 47 REMOVAL (1) Disconnect negative battery cable. (2) Raise vehicle on hoist. (3) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (4) Remove oil pump pickup tube retaining bolt and pull pickup tube from engine block (Fig. 72). Fig. 72 OIL PUMP PICKUP TUBE ASSEMBLY 1 2 3 4 5 6 7 8 9 Fig. 71 OIL PUMP AND VACUUM PUMP 1 2 3 4 5 - VACUUM PUMP CRANKSHAFT SPROCKET OIL PUMP ENGINE BLOCK CRANKSHAFT - BALANCE SHAFT OIL JET RETAINING BOLT OIL JET ENGINE BLOCK CRANKSHAFT BALANCE SHAFT RETAINING BOLTS OIL DIPSTICK TUBE RETAINER RUBBER BUSHING RETAINING BOLT INSTALLATION INSTALLATION (1) Lubricate oil pump rotor with engine oil. (2) Install oil pump in bore in engine block (Fig. 71). 9a - 48 ENGINE RG OIL PUMP (Continued) (3) Install oil pump retaining bolts (Fig. 71). Torque bolts to 10.8N·m. (4) Install crankshaft sprocket (Fig. 71). Torque bolts to 10.8N·m. (5) Install front engine cover (Refer to 9 ENGINE/ENGINE BLOCK/ENGINE COVER INSTALLATION). (6) Install timing belt inner cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (7) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (8) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (9) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (10) Install power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (11) Connect negative battery cable. INSTALLATION (1) Lubricate o-ring on oil pump pickup tube with engine oil. (2) Install pickup tube in engine block and install retaining bolt (Fig. 72). Torque bolt to 32.4N·m. (3) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (4) Refill engine oil to proper level. (5) Connect negative battery cable. Fig. 73 REAR ENGINE VIEW 1 2 3 4 5 6 - SUSPENSION CRADLE ENGINE BLOCK OIL PRESSURE SWITCH OIL TEMPERATURE SENSOR VEHICLE SPEED SENSOR TRANSMISSION (4) Lower vehicle. (5) Start engine and check for leaks. (6) Check and adjust oil level as necessary. OIL PRESSURE SENSOR/ SWITCH OIL TEMPERATURE SENSOR DESCRIPTION The oil temperature sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery (Fig. 74). The oil pressure switch is located on the right side of the engine block. The switch screws into the engines main oil gallery (Fig. 73). REMOVAL (1) Disconnect negative battery cable. (2) Raise vehicle on hoist. (3) Disconnect oil pressure switch electrical connector (Fig. 73). (4) Remove oil pressure switch from engine block. INSTALLATION (1) Apply Mopart Thread Sealant to the switch threads. (2) Install oil pressure switch in engine block. (3) Connect oil pressure switch electrical connector (Fig. 73). DESCRIPTION REMOVAL (1) Disconnect negative battery cable. (2) Raise vehicle on hoist. (3) Disconnect oil temperature sensor electrical connector (Fig. 74). (4) Remove oil temperature sensor from engine block. INSTALLATION (1) Apply Mopart Thread Sealant to the sensor threads. (2) Install oil temperature sensor in engine block. (3) Connect oil temperature sensor electrical connector (Fig. 74) ENGINE RG 9a - 49 OIL TEMPERATURE SENSOR (Continued) Fig. 75 OIL PRESSURE RELIEF VALVE 1 2 3 4 - O-RING OIL PRESSURE RELIEF VALVE CAP OIL PRESSURE RELIEF VALVE SPRING OIL PRESSURE RELIEF VALVE PLUNGER Fig. 74 REAR ENGINE VIEW 1 2 3 4 5 6 - SUSPENSION CRADLE ENGINE BLOCK OIL PRESSURE SWITCH OIL TEMPERATURE SENSOR VEHICLE SPEED SENSOR TRANSMISSION (4) Lower vehicle. (5) Start engine and check for leaks. (6) Check and adjust oil level as necessary. OIL PRESSURE RELIEF VALVE DESCRIPTION The oil pressure relief valve mounts in the front of the engine block and is used to control oil flow through the engines lubrication system (Fig. 75). REMOVAL (1) Remove engine oil pan (Refer to 9 - ENGINE/ LUBRICATION/OIL PAN - REMOVAL). (2) Using special tool VM.1054, remove oil pressure relief valve from engine block (Fig. 76). INSTALLATION (1) Thoroughly clean all components and relief valve pocket in cylinder block. (2) Lubricate all oil pressure relief valve components with engine oil. (3) Install oil pressure relief valve plunger, spring, and cap. Fig. 76 OIL PRESSURE RELIEF VALVE REMOVAL 1 2 3 4 - VM.1054 OIL PRESSURE RELIEF VALVE ENGINE BLOCK OIL PUMP 9a - 50 ENGINE RG OIL PRESSURE RELIEF VALVE (Continued) (4) Using special tool VM.1059, push oil pressure relief valve cap in untill flush with engine block (Fig. 77). Fig. 78 OIL FILTER HOUSING RETAINING NUT Fig. 77 OIL PRESSURE RELIEF VALVE INSTALLATION 1 2 3 4 - 1 - OIL FILTER HOUSING 2 - OIL FILTER HOUSING RETAINING NUT 3 - OIL COOLER VM.1059 OIL PRESSURE RELIEF VALVE ENGINE BLOCK OIL PUMP (5) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). OIL COOLER & LINES REMOVAL (1) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (2) Raise vehicle on hoist. (3) Remove oil filter cap and filter (Refer to 9 ENGINE/LUBRICATION/OIL FILTER - REMOVAL). (4) Remove oil filter housing retaining nut and housing (Fig. 78). (5) Disconnect coolant hoses at cooler (Fig. 79). (6) Remove oil cooler retaining bolt at engine block (Fig. 79). (7) Remove oil cooler retaining stud and remove oil cooler from engine block (Fig. 79). INSTALLATION (1) Clean oil cooler and engine block sealing surfaces. Fig. 79 WATER PUMP AND OIL COOLER ASSEMBLIES 1 2 3 4 5 6 7 - WATER PUMP HOUSING STUDS WATER PUMP RETAINING NUTS OIL COOLER RETAINING STUD OIL COOLER TO ENGINE BLOCK RETAINING BOLT OIL COOLER COOLANT HOSE ENGINE BLOCK ENGINE RG 9a - 51 OIL COOLER & LINES (Continued) (2) Install oil cooler, retaining bolt, and stud (Fig. 79). Torque retaining bolt to 47.1N·m and stud to 50N·m. (3) Connect coolant hoses at cooler (Fig. 79). (4) Install oil filter housing and retaining nut (Fig. 78). Torque retaining nut to 3.5 Kg. (5) Install oil filter cartridge and oil filter cap (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER INSTALLATION). (6) Lower vehicle. (7) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (8) Start engine and check for leaks. (9) Check and adjust oil level as necessary. REMOVAL (1) Raise vehicle on hoist. (2) Remove oil filter cap drain plug and drain oil from oil filter housing (Fig. 81). (3) Remove oil filter cap with suitable oil filter wrench (Fig. 81). OIL FILTER DESCRIPTION The oil filter used on this engine is a cartridge style filter (Fig. 80). Fig. 81 OIL COOLER AND FILTER ASSEMBLY 1 2 3 4 5 - WATER PUMP HOUSING OIL FILTER HOUSING OIL FILTER CAP OIL FILTER CAP DRAIN PLUG OIL COOLER (4) Remove oil filter cartridge from housing. INSTALLATION Fig. 80 OIL FILTER ASSEMBLY 1 - OIL FILTER CAP 2 - DRAIN PLUG 3 - OIL FILTER CARTRIDGE (1) Clean oil filter cap and drain plug with suitable solvent. (2) Install new oil filter cartridge in oil filter housing. (3) Install oil filter cap and drain plug (4) Lower vehicle from hoist. (5) Start engine and check for leaks. (6) Check and adjust oil level as necessary. 9a - 52 ENGINE RG OIL JET DESCRIPTION There are four oil jets installed in the engine block. These oil jets are used to cool and lubricate the piston assemblies (Fig. 82). Fig. 82 OIL JET ASSEMBLY 1 - RETAINING BOLT 2 - OIL JET 3 - O-RING REMOVAL CAUTION: Use caution when removing and installing oil jets. Damage to oil jet nozzle could cause severe engine damage. (1) Disconnect negative battery cable. (2) Raise vehicle on hoist. (3) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (4) Using special tool VM.1060 to hold oil jet. Remove oil jet retaining bolt and remove oil jet from engine block (Fig. 83). INSTALLATION Fig. 83 OIL JET REMOVAL/INSTALLATION 1 2 3 4 - SPECIAL TOOL VM.1060 OIL JET CONNECTING ROD CRANKSHAFT INTAKE MANIFOLD DESCRIPTION CAUTION: Use caution when removing and installaing oil jets. Damage to oil jet nozzle could cause severe engine damage. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - DESCRIPTION) (1) Lubricate o-ring on oil jet. (2) Using special tool VM.1060, install oil jet in engine block (Fig. 83). (3) Install oil jet retaining bolt. Torque bolt to 10.8N·m. (4) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (5) Refill engine oil to proper level. (6) Connect negative battery cable. (1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) REMOVAL INSTALLATION (1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) ENGINE RG 9a - 53 VALVE TIMING STANDARD PROCEDURE - LOCKING ENGINE 90° AFTER TDC (1) Disconnect negative battery cable. (2) Remove starter motor (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL). (3) Rotate engine untill notch in hub is in the following position (Fig. 84). Fig. 85 TDC AND 90 DEGREES AFTER TDC ALIGNMENT PIN LOCATION 1 - ENGINE BLOCK 2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN 3 - FLYWHEEL Fig. 84 CRANKSHAFT HUB ALIGNMENT 1 - VIBRATION DAMPER/CRANKSHAFT PULLEY 2 - CRANKSHAFT HUB NOTCH 3 - VIBRATION DAMPER/CRANKSHAFT PULLEY TO CRANKSHAFT HUB BOLTS (4) Special tool VM.1068 can be install in engine block as shown at this time (Fig. 85). This will lock the engine at 90° after TDC. (5) Remove front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL). (6) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (7) Remove plug in cylinder head cover/intake manifold and insert VM.1053 to lock exhaust camshaft in position (Fig. 86). (8) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL). Fig. 86 EXHAUST CAMSHAFT LOCKING PIN VM.1053 1 - EXHAUST MANIFOLD HEAT SHIELD 2 - EXHAUST CAMSHAFT LOCKING PIN VM.1053 3 - COOLANT TUBE FROM THERMOSTAT HOUSING TO UPPER RADIATOR HOSE 4 - CYLINDER HEAD COVER/INTAKE MANIFOLD 9a - 54 ENGINE RG VALVE TIMING (Continued) (9) Remove plug in cylinder head cover/intake manifold and insert VM.1052 to lock intake camshaft in position (Fig. 87). BALANCE SHAFT DESCRIPTION The 2.5L Common Rail Diesel engine is equipped with two nodular cast iron balance shafts in a cast aluminum carrier. The balance shaft assembly is mounted to the engine block (Fig. 88). Fig. 87 INTAKE CAMSHAFT LOCKING PIN VM.1052 1 2 3 4 5 - TIMING BELT INNER COVER GLOW PLUG ELECTRICAL CONNECTOR CYLINDER HEAD COVER/INTAKE MANIFOLD FUEL RAIL INTAKE CAMSHAFT LOCKING PIN VM.1052 (10) At this point the timing belt can be removed for service. (11) After engine service is completed and timing belt reinstalled, remove both camshaft locking pins from cylinder head cover/intake manifold. (12) Install both camshaft access plugs. (13) Remove 90° after TDC engine locking pin. (14) Install starter motor (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION). (15) Install generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION). (16) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (17) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION). (18) Connect negative battery cable. Fig. 88 BALANCE SHAFT ASSEMBLY 1 2 3 4 5 6 7 8 9 - BALANCE SHAFT OIL JET RETAINING BOLT OIL JET ENGINE BLOCK CRANKSHAFT BALANCE SHAFT RETAINING BOLTS OIL DIPSTICK TUBE RETAINER RUBBER BUSHING RETAINING BOLT OPERATION The balance shaft is driven by the crankshaft. The balance shafts are connected by heelical gears. The dual-counter rotating shafts decrease second order vertical shaking forces caused by component movement. ENGINE RG 9a - 55 BALANCE SHAFT (Continued) REMOVAL (1) Disconnect negative battery cable. (2) Raise vehicle on hoist. (3) Remove oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL). (4) Remove balance shaft assembly (Fig. 89). Fig. 90 TDC AND 90 DEGREES AFTER TDC ALIGNMENT PIN LOCATION 1 - ENGINE BLOCK 2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN 3 - FLYWHEEL bly (Fig. 91). This will ensure proper balance shaft and crankshaft timing after assembly. Fig. 89 BALANCE SHAFT ASSEMBLY 1 2 3 4 5 6 7 8 9 - BALANCE SHAFT OIL JET RETAINING BOLT OIL JET ENGINE BLOCK CRANKSHAFT BALANCE SHAFT RETAINING BOLTS OIL DIPSTICK TUBE RETAINER RUBBER BUSHING RETAINING BOLT INSTALLATION (1) Before installation of the balance shaft assembly, the # 1 cylinder must be brought to TDC. Using special tool VM.1051, roll engine over by hand until tool can be inserted into engine block locking flywheel from turning (Fig. 90). Once the # 1 cylinder is brought to TDC, the balance shaft assembly can be installed. (2) With balance shaft assembly on work bench. Insert special tool VM.1056 into balance shaft assem- Fig. 91 BALANCE SHAFT ALIGNMENT PIN VM.1056 1 - VM.1056 2 - BALANCE SHAFT ASSEMBLY 9a - 56 ENGINE RG BALANCE SHAFT (Continued) (3) Install balance shaft assembly and retaining bolts (Fig. 89). Torque bolts to 32.4N·m. (4) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). (5) Refill engine oil to proper level. (6) Connect negative battery cable. TIMING BELT / CHAIN COVER(S) REMOVAL REMOVAL - TIMING BELT OUTER COVER (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (3) Remove air cleaner housing. (4) Support engine and remove right engine mount and bracket. (5) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (6) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (7) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL). (8) Remove timing belt outer cover retaining bolts and remove cover (Fig. 92). REMOVAL - TIMING BELT INNER COVER (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (3) Remove air cleaner housing. (4) Support engine and remove right engine mount and bracket. (5) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (6) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (7) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL). (8) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (9) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). Fig. 92 TIMING BELT COVER (OUTER) 1 - SEAL 2 - TIMING BELT OUTER COVER 3 - RETAINING BOLTS (10) Remove timing belt idler pulleys (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT IDLER PULLEY - REMOVAL). (11) Using special tool VM.1055, remove camshaft sprockets (Fig. 93). (12) Remove timing belt tensioner (Refer to 9 ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - REMOVAL) . (13) Remove injection pump sprocket (Refer to 14 FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - REMOVAL). (14) Remove timing belt inner cover retaining bolts and remove cover (Fig. 94). INSTALLATION INSTALLATION - TIMING BELT OUTER COVER (1) Install timing belt outer cover seal and cover (Fig. 92). Torque 3mm bolts to 10.8N·m and 8mm bolts to 10.8N·m. (2) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). ENGINE RG 9a - 57 TIMING BELT / CHAIN COVER(S) (Continued) Fig. 93 CAMSHAFT SPROCKET REMOVAL/ INSTALLATION 1 2 3 4 5 - TIMING BELT INNER COVER CAMSHAFT SPROCKET IDLER PULLEYS CAMSHAFT SPROCKET VM.1055 (3) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (4) Install power steering belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (5) Install right engine mount. (6) Install air cleaner housing. (7) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (8) Connect negative battery cable. INSTALLATION - TIMING BELT INNER COVER (1) Install timing belt inner cover to engine front cover seal (Fig. 94). (2) Install timing belt inner cover to cylinder head cover gaskets (Fig. 94). (3) Install timing belt inner cover and retaining bolts (Fig. 94). Torque 10mm bolts to 47.1N·m and 8mm bolts to 10.8N·m. (4) Install injection pump sprocket (Refer to 14 FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - INSTALLATION). (5) Install camshaft sprockets (Fig. 93). Torque bolts to 108N·m. Fig. 94 TIMING BELT COVER - INNER 1 - TIMING BELT COVER TO CYLINDER HEAD COVER GASKET 2 - TIMING BELT COVER TO FRONT ENGINE COVER SEAL 3 - RUBBER GROMMET 4 - BUSHING 5 - TIMING BELT COVER - INNER 6 - RETAINING BOLT 7 - RETAINING BOLT 8 - RETAINING BOLT 9 - BUSHING 10 - RUBBER GROMMET (6) Install timing belt idler pulleys (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT IDLER PULLEY - INSTALLATION). (7) Install timing belt and tensioner (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (8) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). 9a - 58 ENGINE RG TIMING BELT / CHAIN COVER(S) (Continued) (9) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). (10) Install accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION). (11) Install power steering belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (12) Install right engine mount assembly. (13) Install air cleaner housing. (14) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (15) Connect negative battery cable. TIMING BELT IDLER PULLEY REMOVAL (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (3) Remove air cleaner housing. (4) Support engine and remove right engine mount. (5) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (6) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (7) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL). (8) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (9) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). Fig. 95 TIMING BELT AND SPROCKETS 1 2 3 4 5 6 7 8 9 -CAMSHAFT SPROCKETS - INJECTION PUMP SPROCKET - INJECTION PUMP SPROCKET RETAINING NUT - TIMING BELT - TIMING BELT TENSIONER RETAINING BOLT - TIMING BELT TENSIONER - TENSIONER ALIGNMENT PIN - IDLER PULLEY - CAMSHAFT SPROCKET RETAINING BOLT NOTE: Idler pulley retaining bolts are LHD thread. (10) Remove timing belt idler pulleys (Fig. 95). INSTALLATION (1) Install timing belt idler pulleys (Fig. 95). Torque bolts to 47.1N·m. (2) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) . (3) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (4) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). (5) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (6) Install power steering belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (7) Install right engine mount. (8) Install air cleaner housing. (9) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (10) Connect negative battery cable. ENGINE RG 9a - 59 TMNG BELT/CHAIN TENSIONER REMOVAL (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (3) Remove air cleaner housing. (4) Support engine and remove right engine mount. (5) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (6) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (7) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL). (8) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (9) Loosen and remove timing belt tensioner (Fig. 96). INSTALLATION (1) Install timing belt tensioner and retaining bolt (Fig. 96). (2) Adjust timing belt tensioner (Refer to 9 ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - ADJUSTMENTS) . (3) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (4) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). (5) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). Fig. 96 TIMING BELT AND SPROCKETS 1 2 3 4 5 6 7 8 9 -CAMSHAFT SPROCKETS - INJECTION PUMP SPROCKET - INJECTION PUMP SPROCKET RETAINING NUT - TIMING BELT - TIMING BELT TENSIONER RETAINING BOLT - TIMING BELT TENSIONER - TENSIONER ALIGNMENT PIN - IDLER PULLEY - CAMSHAFT SPROCKET RETAINING BOLT (6) Install power steering belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (7) Install right engine mount. (8) Install air cleaner housing. (9) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (10) Connect negative battery cable. 9a - 60 ENGINE RG ADJUSTMENTS ADJUSTMENT - TIMING BELT TENSIONER (1) With timing belt outer cover removed and timing belt installed. (2) Loosen timing belt tensioner (Fig. 97). Fig. 98 TIMING BELT TENSIONER ALIGNMENT 1 2 3 4 5 Fig. 97 TIMING BELT TENSIONER ADJUSTMENT 1 2 3 4 5 - TIMING BELT IDLER PULLEY ENGINE FRONT COVER CRANKSHAFT HUB TIMING BELT TENSIONER TIMING BELT (3) Align timing belt tensioner spring stop with tensioner as shown (Fig. 98) and torque timing belt tensioner retaining bolt to 34.7N·m. (4) Rotate engine 2 complete revolution and then recheck tensioner alignment. Readjust tensioner alignment as necessary. - TENSIONER SPRING STOP TIMING BELT TENSIONER TIMING BELT TENSIONER TIMING BELT TIMING BELT INNER COVER TIMING BELT/CHAIN AND SPROCKETS REMOVAL CAUTION: Before removing the timing belt, the engine must put at 90° after TDC. Failure to do so could result in valve and/or piston damage during reassembly. (Refer to 9 - ENGINE/VALVE TIMING STANDARD PROCEDURE) (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE REMOVAL). (3) Remove air cleaner housing assembly. (4) Support engine and remove right engine mount. (5) Remove power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (6) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL). (7) Remove vibration damper (Refer to 9 ENGINE/ENGINE BLOCK/VIBRATION DAMPER REMOVAL). ENGINE RG 9a - 61 TIMING BELT/CHAIN AND SPROCKETS (Continued) (8) Remove timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (9) Loosen timing belt tensioner and remove timing belt (Fig. 99). Fig. 100 INJECTION PUMP GEAR TIMING MARKS 1 - TIMING MARK ON COVER 2 - TIMING MARK ON INJECTION PUMP SPROCKET 3 - INJECTION PUMP SPROCKET Fig. 99 TIMING BELT AND SPROCKETS 1 2 3 4 5 6 7 8 9 -CAMSHAFT SPROCKETS - INJECTION PUMP SPROCKET - INJECTION PUMP SPROCKET RETAINING NUT - TIMING BELT - TIMING BELT TENSIONER RETAINING BOLT - TIMING BELT TENSIONER - TENSIONER ALIGNMENT PIN - IDLER PULLEY - CAMSHAFT SPROCKET RETAINING BOLT INSTALLATION (1) With both camshaft alignment pins still installed and the engine locked at 90° after TDC. (2) Align timing mark on injection pump sprocket with timing mark on timing belt (Fig. 100). (3) Install timing belt. (4) Adjust the timing belt tensioner (Refer to 9 ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - ADJUSTMENTS) . (5) Remove both camshaft alignment pins from cylinder head cover/intake manifold and engine locking pin from engine block (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE). (6) Install timing belt outer cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (7) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). (8) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (9) Install power steering belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). (10) Install right engine mount. (11) Install air cleaner housing. (12) Install engine cover (Refer to 9 - ENGINE INSTALLATION). (13) Connect negative battery cable. BODY RS 23 - 1 BODY TABLE OF CONTENTS page page BODY DESCRIPTION - VEHICLE IDENTIFICATION . . . . 1 WARNING SAFETY PRECAUTIONS AND WARNINGS . . . 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - WATER LEAKS .1 DIAGNOSIS AND TESTING - WIND NOISE . . . 2 STANDARD PROCEDURE STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 3 STANDARD PROCEDURE - HEAT STAKING . 10 SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BODY LUBRICATION . . . . . . . . . . . . . . . . . . . 12 SPECIAL TOOLS BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . 14 DOORS - SLIDING . . . . . . . . . . . . . . . . . . . . . . . 24 DECKLID/HATCH/LIFTGATE/TAILGATE . . . . . . . 39 EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . 63 INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . 107 WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . 112 BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . 115 BODY material on the interior of vehicle is removed from the repair area. Fire or hazardous conditions, can result. Always have a fire extinguisher ready for use when welding. Disconnect the negative (-) cable clamp from the battery when servicing electrical components that are live when the ignition is OFF. Damage to electrical system can result. Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces. Damage to finish or color can result. Do not hammer or pound on plastic trim panel when servicing interior trim. Plastic panels can break. DESCRIPTION - VEHICLE IDENTIFICATION Throughout this group, references to the DaimlerChrysler Corporation vehicle family identification code are used when describing a procedure that is unique to that vehicle. Refer to Introduction Group of this manual for detailed information on vehicle identification. If a procedure is common to all vehicles covered in this manual, no reference will be made to a vehicle family code. WARNING SAFETY PRECAUTIONS AND WARNINGS WARNING: USE A OSHA APPROVED BREATHING FILTER WHEN SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PERSONAL INJURY CAN RESULT. AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL – BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. DO NOT STAND UNDER A HOISTED VEHICLE THAT IS NOT PROPERLY SUPPORTED ON SAFETY STANDS. PERSONAL INJURY CAN RESULT. CAUTION: When holes must be drilled or punched in an inner body panel, verify depth of space to the outer body panel, electrical wiring, or other components. Damage to vehicle can result. Do not weld exterior panels unless combustible DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - WATER LEAKS Water leaks can be caused by poor sealing, improper body component alignment, body seam porosity, missing plugs, or blocked drain holes. Centrifugal and gravitational force can cause water to drip from a location away from the actual leak point, making leak detection difficult. All body sealing points should be water tight in normal wet-driving conditions. Water flowing downward from the front of the vehicle should not enter the passenger or luggage compartment. Moving sealing surfaces will not always seal water tight under all conditions. At times, side glass or door seals will allow water to 23 - 2 BODY RS BODY (Continued) enter the passenger compartment during high pressure washing or hard driving rain (severe) conditions. Overcompensating on door or glass adjustments to stop a water leak that occurs under severe conditions can cause premature seal wear and excessive closing or latching effort. After completing a repair, water test vehicle to verify leak has stopped before returning vehicle to use. leak and water test to verify that the leak has stopped. Locating the entry point of water that is leaking into a cavity between panels can be difficult. The trapped water may splash or run from the cavity, often at a distance from the entry point. Most water leaks of this type become apparent after accelerating, stopping, turning, or when on an incline. VISUAL INSPECTION BEFORE WATER LEAK TESTS MIRROR INSPECTION METHOD When a leak point area is visually obstructed, use a suitable mirror to gain visual access. A mirror can also be used to deflect light to a limited-access area to assist in locating a leak point. Verify that floor and body plugs are in place, body drains are clear, and body components are properly aligned and sealed. If component alignment or sealing is necessary, refer to the appropriate section of this group for proper procedures. WATER LEAK TESTS WARNING: DO NOT USE ELECTRIC SHOP LIGHTS OR TOOLS IN WATER TEST AREA. PERSONAL INJURY CAN RESULT. When the conditions causing a water leak have been determined, simulate the conditions as closely as possible. • If a leak occurs with the vehicle parked in a steady light rain, flood the leak area with an openended garden hose. • If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonable velocity stream or fan spray of water. Direct the spray in a direction comparable to actual conditions. • If a leak occurs when the vehicle is parked on an incline, hoist the end or side of the vehicle to simulate this condition. This method can be used when the leak occurs when the vehicle accelerates, stops or turns. If the leak occurs on acceleration, hoist the front of the vehicle. If the leak occurs when braking, hoist the back of the vehicle. If the leak occurs on left turns, hoist the left side of the vehicle. If the leak occurs on right turns, hoist the right side of the vehicle. For hoisting recommendations (Refer to LUBRICATION & MAINTENANCE/HOISTING STANDARD PROCEDURE). WATER LEAK DETECTION To detect a water leak point-of-entry, do a water test and watch for water tracks or droplets forming on the inside of the vehicle. If necessary, remove interior trim covers or panels to gain visual access to the leak area. If the hose cannot be positioned without being held, have someone help do the water test. Some water leaks must be tested for a considerable length of time to become apparent. When a leak appears, find the highest point of the water track or drop. The highest point usually will show the point of entry. After leak point has been found, repair the BRIGHT LIGHT LEAK TEST METHOD Some water leaks in the luggage compartment can be detected without water testing. Position the vehicle in a brightly lit area. From inside the darkened luggage compartment inspect around seals and body seams. If necessary, have a helper direct a drop light over the suspected leak areas around the luggage compartment. If light is visible through a normally sealed location, water could enter through the opening. PRESSURIZED LEAK TEST METHOD When a water leak into the passenger compartment cannot be detected by water testing, pressurize the passenger compartment and soap test exterior of the vehicle. To pressurize the passenger compartment, close all doors and windows, start engine, and set heater control to high blower in HEAT position. If engine can not be started, connect a charger to the battery to ensure adequate voltage to the blower. With interior pressurized, apply dish detergent solution to suspected leak area on the exterior of the vehicle. Apply detergent solution with spray device or soft bristle brush. If soap bubbles occur at a body seam, joint, seal or gasket, the leak entry point could be at that location. DIAGNOSIS AND TESTING - WIND NOISE Wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body component alignment, body seam porosity, or missing plugs in the engine compartment or door hinge pillar areas. All body sealing points should be airtight in normal driving conditions. Moving sealing surfaces will not always seal airtight under all conditions. At times, side glass or door seals will allow wind noise to be noticed in the passenger compartment during high cross winds. Over compensating on door or glass adjustments to stop wind noise that occurs under severe conditions can cause premature seal wear and excessive closing or latching effort. After a repair pro- BODY RS 23 - 3 BODY (Continued) cedure has been performed, test vehicle to verify noise has stopped before returning vehicle to use. VISUAL INSPECTION BEFORE TESTS Verify that floor and body plugs are in place and body components are aligned and sealed. If component alignment or sealing is necessary, refer to the appropriate section of this group for proper procedures. ROAD TESTING WIND NOISE (1) Drive the vehicle to verify the general location of the wind noise. (2) Apply 50 mm (2 in.) masking tape in 150 mm (6 in.) lengths along weatherstrips, weld seams or moldings. After each length is applied, drive the vehicle. If noise goes away after a piece of tape is applied, remove tape, locate, and repair defect. POSSIBLE CAUSE OF WIND NOISE • Moldings standing away from body surface can catch wind and whistle. • Gaps in sealed areas behind overhanging body flanges can cause wind-rushing sounds. • Misaligned movable components. • Missing or improperly installed plugs in pillars. • Weld burn through holes. STANDARD PROCEDURE STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR There are many different types of plastics used in today’s automotive environment. We group plastics in three different categories: Rigid, Semi-Rigid, and Flexible. Any of these plastics may require the use of an adhesion promoter for repair. These types of plastic are used extensively on DaimlerChrysler Motors vehicles. Always follow repair material manufacturer’s plastic identification and repair procedures. Rigid Plastics: Examples of rigid plastic use: Fascias, Hoods, Doors, and other Body Panels, which include SMC, ABS, and Polycarbonates. Semi-Rigid Plastics: Examples of semi-rigid plastic use: Interior Panels, Under Hood Panels, and other Body Trim Panels. Flexible Plastics: Examples of flexible plastic use: Fascias, Body Moldings, and upper and lower Fascia Covers. Repair Procedure: The repair procedure for all three categories of plastics is basically the same. The one difference is the material used for the repair. The materials must be specific for each substrate, rigid repair material for rigid plastic repair, semi-rigid repair material for semi-rigid plastic repair and flexible repair material for flexible plastic repair. Adhesion Promoter/Surface Modifier: Adhesion Promoters/Surface Modifiers are required for certain plastics. All three categories may have plastics that require the use of adhesion promoter/ surface modifiers. Always follow repair material manufacturer’s plastic identification and repair procedures. SAFETY PRECAUTION AND WARNINGS WARNING: • EYE PROTECTION SHOULD BE USED WHEN SERVICING COMPONENTS. PERSONAL INJURY CAN RESULT. • USE AN OSHA APPROVED BREATHING MASK WHEN MIXING EPOXY, GRINDING, AND SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PERSONAL INJURY CAN RESULT. • AVOID PROLONGED SKIN CONTACT WITH RESIN, PETROLEUM, OR ALCOHOL BASED SOLVENTS. PERSONAL INJURY CAN RESULT. • DO NOT VENTURE UNDER A HOISTED VEHICLE THAT IS NOT PROPERLY SUPPORTED ON SAFETY STANDS. PERSONAL INJURY CAN RESULT. NOTE: • When holes must be drilled or cut in body panels, verify locations of internal body components and electrical wiring. Damage to vehicle can result. • Do not use abrasive chemicals or compounds on undamaged painted surfaces around repair areas. Damage to finish can result. 23 - 4 BODY RS BODY (Continued) RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION ASA ACRYLONITRILE STYRENE ACRYLITE LURAN S CONSOLES, GRILLES ABS ACRYLONITRILE BUTADIENE STYRENE TERLURAN 9A9 PILLARS, CONSOLES, GRILLES ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT PANELS ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN, CYCLOVIN DOOR PANELS, GRILLES, TRIM BMC BULK MOLDING COMPOUND BMC FENDER EXTENSIONS EMA EHTYLENE METHYL ACRYLATE/IONOMER SURLYN, EMA, IONOMER BUMPER GUARDS, PADS METTON METTON METTON GRILLES, KICK PANELS, RUNNING BOARDS MPPO MODIFIED POLYPHENYLENE OXIDE MPPO SPOILER ASSEMBLY PA POLYAMID ZYTEL, VYDYNE, PA, MINLON FENDERS, QUARTER PANELS PET THERMOPLASTIC POLYESTER RYNITE TRIM PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS PBTP POLYBUTYLENE THEREPTHALATE PBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS, GRILLES PBTP/EEBC POLYBUTYLENE THEREPTHALATE/EEBC ALLOY BEXLOY, 9M9, PBTP/EEBC FASCIAS, ROCKER PANEL, MOLDINGS PC POLYCARBONATE LEXAN, MERLON, CALIBRE, MAKROLON PC TAIL LIGHT LENSES, IP TRIM, VALANCE PANELS PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS, PULSE DOORS, INSTRUMENT PANELS PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN, MARLEX, PRFAX, NORYL, GTX, PPO INTERIOR TRIM, DOOR PANELS, SPLASH SHIELDS, STEERING COLUMN SHROUD PPO/PA POLYPHENYLENE/ POLYAMID PPO/PA, GTX 910 FENDERS, QUARTER PANELS PR/FV FIBERGLASS REINFORCED PLASTIC FIBERGLASS, FV, PR/FV BODY PANELS PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH PANELS RTM RESIN TRANSFER MOLDING COMPOUND RTM BODY PANELS SMC SHEET MOLDED COMPOUND SMC BODY PANELS TMC TRANSFER MOLDING COMPOUND TMC GRILLES BODY RS 23 - 5 BODY (Continued) CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION UP UNSATURATED POLYESTER (THERMOSETTING) SMC, BMC, TMC, ZMC, IMC, XSMC, UP GRILLE OPENING PANEL, LIFTGATES, FLARESIDE FENDERS, FENDER EXTENSIONS EEBC ETHER/ESTER BLOCKED CO-POLYMER EEBC BUMPERS EEBC/PBTP EEBC/POLYBUTYLENE TEREPTHALATE EEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS EMPP ETHYLENE MODIFIED POLYPROPYLENE EMPP BUMPER COVERS EPDM ETHYLENE/ PROPROPYLENE DIENE MONOMER EPDM, NORDEL, VISTALON BUMPERS EPM ETHYLENE/ PROPROPYLENE COPOLYMER EPM FENDERS MPU FOAM POLYURETHANE MPU SPOILERS PE POLYETHYLENE ALATHON, DYLAN, LUPOLEN, MARLEX - PP POLYPROPYLENE (BLENDS) NORYL, AZDEL, MARLOX, DYLON, PRAVEX INNER FENDER, SPOILERS, KICK PANELS PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS PUR/PC PUR/PC ALLOY TEXIN BUMPERS PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE INSULATION, STEERING WHEELS RIM REACTION INJECTED MOLDED POLYURETHANE RIM, BAYFLEX FRONT FASCIAS, MODULAR WINDOWS RRIM REINFORCED REACTION INJECTED MOLDED PUR, RRIM FASCIAS, BODY PANELS, BODY TRIMS TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS, CLADDINGS TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX, SANTOPRENE, VISAFLEX, ETA, APEX, TPO, SHIELDS, CLADDINGS BUMPERS, END CAPS, TELCAR, RUBBER, STRIPS, SIGHT, INTERIOR B POST TPP THERMOPOLYPROPYLENE TPP BUMPERS TPU THERMOPOLYURETHANE, POLYESTER TPU, HYTREL, TEXIN, ESTANE BUMPERS, BODY SIDE, MOLDINGS, FENDERS, FASCIAS 23 - 6 BODY RS BODY (Continued) PANEL SECTIONING PANEL REINFORCEMENT If it is required to section a large panel for a plastic repair, it will be necessary to reinforce the panel (Fig. 1). To bond two plastic panels together, a reinforcement must overlap both panels. The panels must be “V’d” at a 20 degree angle. The area to be reinforced should be washed, then sanded. Be sure to wipe off any excess soap and water when finished. Lightly sand or abrade the plastic with an abrasive pad or sandpaper. Blow off any dust with compressed air or wipe with a clean dry rag. Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing. Reinforcements can be made with several applications of glass cloth saturated with structural adhesive. Semi-rigid or flexible repair materials should be used for semi-rigid or flexible backing reinforcement (Fig. 2) and (Fig. 3). Open meshed fiberglass dry wall tape can be used to form a reinforcement. The dry wall tape allows the resin to penetrate through and make a good bond between the panel and the adhesive. Structurally, the more dry wall tape used, the stronger the repair. Another kind of repair that can be done to repair large cracks and holes is to use a scrap piece of similar plastic and bond with structural adhesive. The reinforcement should cover the entire break and should have a generous amount of overlap on either side of the cracked or broken area. When repairing plastic, the damaged area is first “V’d” out, or beveled. Large bonding areas are desirable when repairing plastic because small repairs are less likely to hold permanently. Beveling the area around a crack at a 20 degree angle will increase the bonding surface for a repair (Fig. 4). It is recommended that sharp edges be avoided because the joint may show through after the panel is refinished. Fig. 1 PANEL SECTIONING 1 2 3 4 - EXISTING PANEL NEW PANEL PANEL ADHESIVE BONDING STRIP When bonding plastic panels, Follow repair material manufacturers recommendations. Be sure that enough adhesive has been applied to allow squeeze out and to fill the full bond line. Once the pieces have been brought together, do not move them until the adhesive is cured. The assembly can be held together with clamps, rivets, etc. A faster cure can be obtained by heating with a heat lamp or heat gun. After the parts have been bonded and have had time to cure, rough sand the seam and apply the final adhesive filler to the area being repaired. Smooth the filler with a spreader, wooden tongue depressor, or squeegee. For fine texturing, a small amount of water can be applied to the filler surface while smoothing. The cured filler can be sanded as necessary and, as a final step, cleanup can be done with soapy water. Wipe the surface clean with a dry cloth allowing time for the panel to dry before moving on with the repair. Fig. 2 SOFTENED EDGES 1 - SOFTENED EDGES 2 - PANEL ADHESIVE 3 - BONDING STRIP Fig. 3 PANEL REINFORCEMENT 1 - PANEL ADHESIVE 2 - REINFORCEMENT BODY RS 23 - 7 BODY (Continued) Fig. 4 BEVELING ANGLE - 20 DEGREE • Panel repair for both flexible and rigid panels are basically the same. The primary difference between flexible panel repair and rigid panel repair is in the adhesive materials used (Fig. 5). • The technician should first decide what needs to be done when working on any type of body panel. One should determine if it is possible to return the damage part to its original strength and appearance without exceeding the value of the replacement part. • When plastic repairs are required, it is recommended that the part be left on the vehicle when every possible. That will save time, and the panel will remain stationary during the repair. Misalignment can cause stress in the repair areas and can result in future failure. Fig. 6 DAMAGE COMPONENT 1 - PUNCTURE PANEL SURFACE PREPARATION If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the panel to achieve a successful repair. All spider web cracks leading away from a damaged area must be stopped or removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the crack farthest away from the damage. If spider web cracks can not be stopped, the panel would require replacement. The surfaces around the damaged area should be stripped of paint and freed from wax and oil. Scuff surfaces around repair area with 360 grit wet/dry sandpaper, or equivalent, to assure adhesion of repair materials. PATCHING PANELS Fig. 5 FIBERGLASS TAPE VISUAL INSPECTION Composite materials can mask the severity of an accident. Adhesive bond lines, interior structure of the doors, and steel structures need to be inspected carefully to get a true damage assessment. Close inspection may require partial removal of interior trim or inner panels. Identify the type of repair: Puncture or Crack Damage that has penetrated completely through the panel. Damage is confined to one general area; a panel section is not required. However, a backer panel, open fiberglass tape, or matted material must be bonded from behind (Fig. 7) (Fig. 6). An panel that has extensive puncture type damage can be repaired by cutting out the damaged material (Fig. 7). Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is damaged. The piece cut out can be used as a template to shape the new patch. It is not necessary to have access to the back of the panel to install a patch. Bevel edges of cutout at 20 degrees to expose a larger bonding area on the outer side. This will allow for an increased reinforcement areas. 23 - 8 BODY RS BODY (Continued) Fig. 8 FABRICATED PANEL Fig. 7 DAMAGED PANEL CUTOUT AND PATCH 1 2 3 4 - CUTOUT DAMAGED BODY PANEL 4 MM (0.160 IN.) HOLES PATCH CUT TO SIZE PANEL PATCH FABRICATIONS A patch can be fabricated from any rigid fiberglass panel that has comparable contour with the repair area. Lift gates and fenders can be used to supply patch material. If existing material is not available or compatible, a patch can be constructed with adhesive and reinforcement mesh (dry wall tape). Perform the following operation if required: (1) Cover waxed paper or plastic with adhesive backed nylon mesh (dry wall tape) larger than the patch required (Fig. 8). (2) Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area. (3) Apply a liberal coat of adhesive over the reinforcement mesh (Fig. 8). If necessary apply a second or third coat of adhesive and mesh after firs coat has cured. The thickness of the patch should be the same as the repair area. (4) After patch has cured, peel waxed paper or plastic from the back of the patch. (5) If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh for added strength. 1 2 3 4 - STRUCTURAL ADHESIVE FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE WIDTH OF V-GROOVE WAXED PAPER (6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around cutout. (7) Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center of one side. (8) Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper. (9) Mix enough adhesive to cover one side of all support squares. (10) Apply adhesive to cover one side of all support squares. (11) Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive sandwiched between the panel and squares (Fig. 9). PANEL PATCH INSTALLATION (1) Make a paper or cardboard pattern the size and shape of the cutout hole in the panel. (2) Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting surfaces. (3) Using the pattern as a guide, cut the patch to size. (4) Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to sustain the patch in the cutout. (5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole (Fig. 7). Fig. 9 SECURE SUPPORT SQUARES TO BODY PANEL 1 - SUPPORT SQUARES 2 - SCREWS 3 - DAMAGED BODY PANEL BODY RS 23 - 9 BODY (Continued) (12) Position patch in cutout against support squares and adjust patch until the gap is equal along all sides (Fig. 10). (13) Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch. (14) Apply a coat of adhesive to the exposed ends of the support squares (Fig. 11). (15) Install screws to hold the patch to support squares (Fig. 12). Tighten screws until patch surface is flush with panel surface. (16) Allow adhesive to cure, and remove all screws. (17) Using a 125 mm (5 in.) 24 grit disc grinder, grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2 mm (0.080 in.) deep path across the gaps around the patch (Fig. 13). With compressed air, blow dust from around patch. (18) Apply adhesive backed nylon mesh (dry wall tape) over gaps around patch (Fig. 14). (19) Mix enough adhesive to cover the entire patch area. (20) Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce finish grinding. Use two to three layers of mesh and adhesive to create a stronger repair (Fig. 15). Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES 1 - APPLICATOR 2 - SUPPORT SQUARES 3 - ADHESIVE Fig. 12 INSTALL SCREWS 1 - PATCH 2 - GAP Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN 1 - CUTOUT 2 - SUPPORT SQUARES 23 - 10 BODY RS BODY (Continued) Fig. 15 COVER MESH WITH ADHESIVE Fig. 13 GRIND SURFACE 1 - PATCH 2 - GAP 3 - DISC GRINDER 1 2 3 4 - ADHESIVE - MESH - PATCH - SPREADER STANDARD PROCEDURE - HEAT STAKING Fig. 14 COVER GAPS WITH MESH 1 - GROUND DOWN AREA 2 - PATCH 3 - MESH PATCHED PANEL SURFACING After patch panel is installed, the patch area can be finished using the same methods as finishing other types of body panels. If mesh material is exposed in the patched area, grind surface down, and apply a coat of high quality rigid plastic body filler. Prime, block sand, and paint as required. (1) Remove trim panel. (2) Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. (3) Heat stake the components. (a) If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. (b) If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. (4) Allow the repaired area to cool and verify the repair. (5) Install trim panel. BODY RS 23 - 11 BODY (Continued) SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. All seat belt anchor bolts 39 29 — Armrest shoulder bolt 29 21 — Bench seat riser bolts 48 35 — Bench seat track nuts 48 35 — Quad bucket seat track to cushion frame bolts 40 30 — Bucket seat back pivot bolts 33 24 — Center seat to seat track bolts 24 17 — Child seat module screws (bench seats) 7 — 62 Child seat module screws (quad seats) 13.5 10 — Crossmember to radiator closure panel bolts 28 21 — Door check strap to door end frame 12 — 105 Door latch to door end frame bolts 10 — 89 Floor latch to seat cushion frame bolts 27 19 — Front cover to seat track screws 4 — 32 Front door hinge to hinge pillar bolts 34 25 — Front door hinge to door nuts and bolts 34 25 — Front door latch striker bolts 28 21 — Front/quad seat cushion bolts 28.5 21 — Front seat belt retractor bolts 38 28 — Front seat riser to floor nuts 60 44 — Front seat track cover screws 4 — 35 Front seat riser to seat track nuts 81 60 — Front seatback pivot bolts 54 40 — Front seatback recliner nut 12 — 105 Front seatback assist strap screws 2.5 — 22 Grocery bag holder screws 2 — 17 Hinge to liftgate bolts 33 24 — Hood latch to bolts 13.5 10 — Hood latch striker bolts 13.5 10 — Hood hinge to hood bolts 13.5 10 — Liftgate exterior handle outer screws 20 15 — Liftgate exterior handle inner bolts 40 30 — Lifgate hinge to roof header bolts 33 24 — Liftgate latch bolts 16 12 — Liftgate latch striker bolts 28 21 — Liftgate lift motor link to liftgate 28 21 — Liftgate spoiler bolts 9 — 80 23 - 12 BODY RS BODY (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Lifgate stabalizer wedge striker to D-pillar bolts 3 — 30 Luggage rack crossbar fasteners 4 — 35 Lumbar support handle screw 1 — 9 Pivot bolt to the body half of hood hinge 28 21 — Prop assembly to lifgate bolts 28 21 — Rear door glass to regulator bolt 11 8 — Rear door hinge to B-pillar bolt 28 20 — Rear door hinge to door bolt 28 20 — Rear door latch striker 28 20 — Rear latch to sliding door end frame 28 20 — Rear seat back to seat cushion bolt 27 19 — Recliner to seat back frame 12 9 — Seatback frame upper rail 8 — 71 Seatback hinge bolt 48 35 — Seatback hinge cover screws 2.3 — 20 Shoulder belt turning loop onto height adjuster 39 29 — Sliding door center hinge adjusting bolt 15 — 130 Sliding door glass nuts 3.4 — 30 Sliding door latch striker 28 21 — Sliding door to roller arm bracket 12 9 — Storage bin track quide to seat riser 3.5 — 31 Support cylinders to liftgate 28 21 — BODY LUBRICATION LUBRICATION REQUIREMENTS Body mechanisms and linkages should be inspected, cleaned, and lubricated, as required, to maintain ease of operation and to provide protection against rust and wear. When performing other under hood services, the hood latch release mechanism and safety catch should be inspected, cleaned, and lubricated. During the winter season, external door lock cylinders should be lubricated to assure proper operation when exposed to water and ice. Prior to the application of any lubricant, the parts concerned should be wiped clean to remove dust and grit. If necessary, a suitable solvent can be used to clean the item to be lubricated. After lubricating a component, any excess oil or grease should be removed. LUBRICANT APPLICATION DOOR LOCK CYLINDERS (1) Apply a small amount of lubricant directly into the lock cylinder. (2) Apply a small amount of lubricant to the key. (3) Insert key into lock cylinder and cycle the mechanism from the locked to the unlocked position. NOTE: Do not add more lubricant. (4) Cycle the lock cylinder mechanism several times to allow the lubricant to flow throughout the cylinder. (5) Wipe all lubricant from exterior of lock cylinder and key. ALL OTHER BODY MECHANISMS (1) Clean component as described above. (2) Apply specified lubricant to all pivoting and sliding contact areas of component. LUBRICANT USAGE ENGINE OIL • Door Hinges – Hinge Pin and Pivot Contact Areas • Hood Hinges – Pivot Points • Liftgate Hinges BODY RS 23 - 13 BODY (Continued) MOPART SPRAY WHITE LUBE OR EQUIVALENT • Door Check Straps • Liftgate Latches • Liftgate Prop Pivots • Ash Receiver • Fuel Filler Door Remote Control Latch Mechanism • Parking Brake Mechanism • Sliding Seat Tracks • Liftgate Latch MOPART Multipurpose GREASE OR EQUIVALENT • All Other Hood Mechanisms MOPART LOCK CYLINDER LUBRICANT OR EQUIVALENT • Door Lock Cylinders • Liftgate Lock Cylinder SPECIAL TOOLS BODY INDEX DESCRIPTION FIGURE STICK, TRIM C 4755 16 REMOVER, MOLDINGS C-4829 17 PLIERS, HEADLINER CLIP 6967 18 Fig. 16 STICK, TRIM C 4755 Fig. 17 REMOVER, MOLDINGS C-4829 Fig. 18 PLIERS, HEADLINER CLIP 6967 23 - 14 DOOR - FRONT RS DOOR - FRONT TABLE OF CONTENTS page APPLIQUE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . CHECK STRAP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . DOOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . DOOR GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . FRAME CLOSEOUT MOLDING REMOVAL – A-PILLAR, HEADER, OR B-PILLAR . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION – A-PILLAR, HEADER, OR B-PILLAR . . . . . . . . . . . . . . . . . . . . . . . HINGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . LATCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . 14 . . . . . 14 . . . . . 14 . . . . . 15 . . . . . 16 . . . . . 16 . . . . . 17 . . . . . 17 . . . . . 17 . . . . . 18 . . . . . 18 . . . . . 18 page INSTALLATION . . . . LATCH STRIKER REMOVAL . . . . . . . . INSTALLATION . . . . LOCK CYLINDER REMOVAL . . . . . . . . INSTALLATION . . . . TRIM PANEL REMOVAL . . . . . . . . INSTALLATION . . . . WATERSHIELD REMOVAL . . . . . . . . INSTALLATION . . . . WINDOW CRANK REMOVAL . . . . . . . . INSTALLATION . . . . WINDOW REGULATOR REMOVAL . . . . . . . . INSTALLATION . . . . EXTERIOR HANDLE REMOVAL . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . . . . . 23 APPLIQUE CHECK STRAP REMOVAL REMOVAL (1) Roll door glass down. (2) Remove outer door belt molding. (3) Disengage clips holding front edge of applique to door frame. (4) Remove applique from vehicle (Fig. 1). (1) Remove front door trim panel. (2) Remove front door watershield (Refer to 23 BODY/DOOR - FRONT/WATERSHIELD - REMOVAL). (3) Remove front door speaker, if equipped. (4) Remove bolts attaching door check strap to A-pillar. (5) Remove nuts attaching check strap to door end frame (Fig. 2). (6) Remove check strap from door through speaker hole. INSTALLATION (1) Position applique on vehicle. (2) Hook rear edge of applique over rear edge of door frame and seat applique bottom edge on sheet metal. (3) Engage clips to hold front edge of applique to door frame. (4) Install outer door belt molding. INSTALLATION (1) Position check strap on door through speaker hole. (2) Install nuts to attach check strap to door end frame. Tighten nuts to 11 N·m (90 in. lbs.) torque. (3) Install bolts to attach check strap to A-pillar. Tighten bolts to 12 N·m (105 in. lbs.) torque. (4) Install door speaker, if equipped. (5) Install front door trim panel. DOOR - FRONT RS 23 - 15 CHECK STRAP (Continued) DOOR REMOVAL Fig. 1 FRONT DOOR APPLIQUE 1 2 3 4 (1) Remove front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/LF WHEELHOUSE SPLASH SHIELD - REMOVAL) (2) Disengage clips attaching door harness wire connector to inner fender brace. (3) Disconnect positive lock slide on the side of the wire connectors (Fig. 3). (4) Depress lock tab attaching wire connector halves together. (5) Disconnect door harness from body wiring harness. (6) Remove bolts attaching door check strap to A-pillar (Fig. 4). (7) Support door on suitable lifting device. (8) Remove bolts attaching lower hinge to door end frame (Fig. 5). (9) Steady door on lifting device and remove bolts attaching upper hinge to door end frame. (10) Remove door from vehicle. - GLASS RUN WEATHERSTRIP - CLIPS - APPLIQUE - FRONT DOOR Fig. 3 FRONT DOOR WIRE CONNECTORS Fig. 2 FRONT DOOR CHECK STRAP 1 - FRONT DOOR 2 - DOOR CHECK STRAP 1 2 3 4 5 6 - LOCK TAB POSITIVE LOCK BODY HARNESS CONNECTOR FRONT FENDER DOOR HARNESS CONNECTOR BODY HARNESS 23 - 16 DOOR - FRONT RS DOOR (Continued) INSTALLATION NOTE: If new hinge pins are to be used, verify that the knurling on the hinge pin is aligned with the knurling on in the door hinge prior to driving in the pin. Also, verify that the hinge pin is fully seated to the door hinge and a new retaining clip is installed. Fig. 4 FRONT DOOR - HINGE PIN REMOVAL 1 2 3 4 5 6 - FRONT DOOR - CLIP - A-PILLAR - HINGE PIN - CLIP - DOOR CHECK STRAP (1) Support door on suitable lifting device. (2) Position door to vehicle. Verify net pierce nubbin is engaged if reusing original hinges. (3) Steady door on lifting device and install bolts attaching upper hinge to door end frame. Tighten bolts to 34 N·m (25 ft. lbs.) torque. (4) Install bolts attaching door check strap to A-pillar. Tighten bolts to 12 N·m (105 in. lbs.) torque. (5) Install bolts attaching lower hinge to door end frame. Tighten bolts to 34 N·m (25 ft. lbs.) torque. Align door to achieve equal spacing to surrounding body panels. Panels should be flush across all gaps. (6) Connect door harness into body wiring harness. (7) Connect positive lock slide on the side of the wire connectors. (8) Connect clips attaching door harness wire connector to inner fender brace. (9) Install front wheelhouse splash shield. (10) Verify door operation and alignment. Adjust as necessary. DOOR GLASS REMOVAL Fig. 5 FRONT DOOR - HINGE BOLT REMOVAL 1 2 3 4 - FRONT DOOR UPPER HINGE CHECK STRAP LOWER HINGE (1) Remove watershield. (Refer to 23 - BODY/ DOOR - FRONT/WATERSHIELD - REMOVAL) (2) Remove inner belt molding.(Refer to 23 BODY/WEATHERSTRIP/SEALS/FDR INNER BELT WEATHERSTRIP - REMOVAL) (3) Remove outer belt molding.(Refer to 23 BODY/WEATHERSTRIP/SEALS/FDR OUTER BELT MOLDING - REMOVAL) (4) Position glass to gain access to front and rear regulator lift plates through front and rear access holes in door panel. (5) Remove clips attaching door glass to regulator lift plates (Fig. 6). (6) Remove glass from regulator lift plates. (7) Disengage glass from glass run weatherstrip. (8) Insert front of glass between glass run channel and outer door panel. (9) Lift glass upward and out of exterior side of the opening at top of door (Fig. 7). (10) Remove glass from vehicle. DOOR - FRONT RS 23 - 17 DOOR GLASS (Continued) Fig. 6 FRONT DOOR GLASS CLIPS 1 2 3 4 5 - DOOR GLASS GLASS LIFT PLATE CLIP GUIDE RAIL REGULATOR LIFT PLATE INSTALLATION (1) Install clips that attach door glass to regulator lift plates (Fig. 6). (2) Place glass in window opening with front inserted between run channel and outer door panel (Fig. 7). (3) Lower glass downward into door. (4) Insert ends of glass into glass run weatherstrip channels at front and rear of door. (5) Place glass in position on regulator lift plates. (6) Snap glass mounting studs into clips on regulator lift plates. (7) Install radio speaker, if equipped. (8) Install outer belt molding. (Refer to 23 - BODY/ WEATHERSTRIP/SEALS/FRONT DOOR OUTER BELT MOLDING - INSTALLATION) (9) Install inner belt molding.(Refer to 23 - BODY/ WEATHERSTRIP/SEALS/FRONT DOOR INNER BELT MOLDING - INSTALLATION) (10) Verify door glass operation and fit. (11) Install watershield. (Refer to 23 - BODY/ DOOR - FRONT/WATERSHIELD - INSTALLATION) Fig. 7 FRONT DOOR GLASS 1 - DOOR GLASS 2 - FRONT DOOR 3 - GLASS RUN CHANNEL FRAME CLOSEOUT MOLDING REMOVAL – A-PILLAR, HEADER, OR B-PILLAR (1) Roll door glass down. (2) Using a hook tool, pull front door frame closeout molding from window frame channel (Fig. 8). (3) Remove closeout molding from vehicle. INSTALLATION – A-PILLAR, HEADER, OR B-PILLAR (1) Position closeout molding in window frame. (2) Insert closeout molding into window frame channel starting at the corners and working inward. (3) Verify door glass operation. 23 - 18 DOOR - FRONT RS FRAME CLOSEOUT MOLDING (Continued) LATCH REMOVAL Fig. 8 FRONT DOOR FRAME CLOSEOUT MOLDINGS 1 2 3 4 5 - FRONT FRONT FRONT FRONT FRONT DOOR DOOR DOOR DOOR DOOR (1) Roll door glass up. (2) Remove front door trim panel. (Refer to 23 BODY/DOOR - FRONT/TRIM PANEL - REMOVAL) (3) Remove watershield as necessary to gain access to the outside door handle. (4) Through access hole at rear of inner door panel, disconnect wire connector from power door lock motor, if equipped. (5) Disengage clips holding linkage to door latch (Fig. 9). (6) Remove linkages from door latch. (7) Remove screws attaching door latch to door end frame (Fig. 10). (8) Remove door latch from door. FRAME HEADER CLOSEOUT MOLDING FRAME B-PILLAR CLOSEOUT MOLDING FRAME A-PILLAR CLOSEOUT MOLDING FRAME HINGE REMOVAL (1) Release front door latch and open door. (2) Mark hinge foot print on both door and pillar to aid when installing door. (3) Support door on suitable lifting device. (4) Remove bolts attaching front door to door hinge. (5) Remove bolts attaching hinge to pillar. (6) Remove door hinge from vehicle. INSTALLATION CAUTION: When installing a new hinge, make sure that the head of each hinge pin is fully seated into the door hinge. Also, remove the plastic shipping clip and replace it with the correct metal retaining clip once the hinge pin is seated. (1) Paint hinge prior to installation, if necessary. (2) Position door hinge on vehicle. (3) Install bolts attaching hinge to pillar. Tighten bolts to 34 N·m (25 ft. lbs.). (4) Install bolts attaching front door to door hinge. Tighten bolts to 34 N·m (25 ft. lbs.). (5) Align door to achieve equal spacing to surrounding body panels. Panels should be flush across all gaps. (6) Verify door alignment and operation. Adjust as necessary. Fig. 9 LATCH ASSEMBLY 1 2 3 4 5 - OUTSIDE HANDLE TO LATCH LINK KEY CYLINDER TO LATCH LINK LATCH ASSEMBLY INSIDE HANDLE LINK AND SLEEVE LOCK KNOB LINK INSTALLATION NOTE: The screws attaching the door latch to the door end frame have nylon patches on the threads. All screws must be replaced when the latch has been removed. (1) Insert inside handle latch link to door latch and engage clip (Fig. 9). DOOR - FRONT RS 23 - 19 LATCH (Continued) Fig. 10 FRONT DOOR LATCH 1 - FRONT DOOR 2 - LATCH ASSEMBLY 7 - INSIDE HANDLE LINK (2) Place door latch in position on door end frame. (3) Install screws attaching door latch to door end frame. Tighten screws to 10 N·m (90 in. lbs.) torque (Fig. 10). (4) Insert other linkages to door latch and engage clips. (5) Connect wire connector into power door lock motor, if equipped. (6) Insert a hex wrench through the elongated hole located in the door shut face above the latch. (7) Loosen allen head screw. (8) Pull outward on the outside door handle and release. (9) Tighten allen head screw. (10) Verify door latch and power door lock operation. (11) Install watershield and front door trim panel. Fig. 11 DOOR LATCH STRIKER 1 - B-PILLAR 2 - SHIM 3 - DOOR LATCH STRIKER INSTALLATION (1) Position latch striker and any shims retrieved on vehicle. (2) Loosely install screws attaching latch striker to B-pillar. (3) Align latch striker to outline on B-pillar made previously. (4) Tighten fasteners to 28 N·m (21 ft. lbs.) torque. (5) Verify door fit and operation. Adjust latch striker as necessary. LOCK CYLINDER REMOVAL LATCH STRIKER REMOVAL (1) Mark outline of door striker on B-pillar to aid in installation. (2) Remove screws attaching door latch striker to B-pillar (Fig. 11). (3) Remove door latch striker from vehicle. (4) Retrieve any shims found between latch striker and B-pillar. (1) Roll door glass up. (2) Remove front door watershield as necessary to gain access to the outside door handle. (Refer to 23 BODY/DOOR FRONT/WATERSHIELD REMOVAL) (3) Through access hole at rear of inner door panel, disconnect Vehicle Theft Security System (VTSS) switch connector from door harness, if equipped. (4) Disengage push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if equipped. 23 - 20 DOOR - FRONT RS LOCK CYLINDER (Continued) (5) Disengage clip holding door latch linkage to door latch (Fig. 12). (6) Remove latch linkage from latch. (7) Disengage clip holding door lock linkage to door latch. (8) Remove lock linkage from latch. (9) Remove nuts attaching outside door handle to door outer panel. (10) Remove outside door handle from vehicle. (11) Disengage clip holding lock cylinder into outside handle. (12) Pull lock cylinder from door handle. INSTALLATION (1) Engage clip into outside handle to hold lock cylinder (Fig. 12). (2) With link arm toward rear of vehicle, push lock cylinder into door handle until clip snaps into place. (3) Insert lock linkage into door latch. (4) Engage clip to hold door lock linkage to latch. (5) Insert latch linkage into door latch. (6) Engage clip to hold door latch linkage to latch. (7) Install push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if equipped. (8) Connect VTSS switch connector into door harness, if equipped. (9) Verify door latch operation. (10) Install watershield and door trim panel. TRIM PANEL REMOVAL (1) Remove the plug and remove screw attaching door pull cup to inner door panel. (2) Remove switch bezel and disconnect power window/memory switch. (3) Remove screws attaching trim panel to door from below map pocket. (4) If equipped, remove window crank. (Refer to 23 - BODY/DOOR - FRONT/WINDOW CRANK REMOVAL) (5) Remove screw holding door trim to door panel from behind inside latch release handle. (6) Disengage clips attaching door trim to door frame around perimeter of panel. (7) Lift trim panel upward to disengage flange from inner belt molding at top of door. (8) Tilt top of trim panel away from door to gain access to latch linkage. (9) Disengage clip attaching linkage rod to inside latch release handle (Fig. 13). (10) Separate linkage rod from latch handle. (11) Disconnect the power door switch, courtesy lamp electrical connectors. Fig. 12 OUTSIDE DOOR HANDLE 1 2 3 4 5 - CLIP LOCK CYLINDER KEY CYLINDER TO LATCH LINK OUTSIDE HANDLE TO LATCH LINK LOCK KNOB LINK 6 - FRONT DOOR 7 - KEY POSITION SWITCH 8 - OUTSIDE HANDLE DOOR - FRONT RS 23 - 21 TRIM PANEL (Continued) (12) Remove front door trim panel from vehicle. WATERSHIELD REMOVAL (1) Remove door trim panel. (2) Remove the front door speaker. (3) Peel watershield away from adhesive around perimeter of inner door panel. INSTALLATION (1) Insure that enough adhesive remains to securely retain the water dam. Replace as necessary. (2) Place the sound shield into position and press securely to adhesive making sure to properly route wiring and linkages. (3) Install door trim panel. Fig. 13 INSIDE DOOR HANDLE LINKAGE 1 2 3 4 5 - DOOR LATCH HANDLE DOOR TRIM LATCH LINKAGE CLIP MEMORY SEAT SWITCH INSTALLATION (1) Hold top of trim panel away from door to gain access to latch linkage. (2) Place linkage rod in position on latch handle. (3) Engage clip to hold linkage rod to inside latch release handle. (4) Place front door trim panel in position on door. (5) Install trim panel into inner belt molding at top of door. (6) Install clips to attach door trim to door frame around perimeter of panel. (7) If equipped, install screw to attach door trim to door panel behind inside latch release handle. (8) If equipped, connect power switch into wire connector. (9) Place power accessary switch in position on door trim. (10) Connect wire connector into memory seat/mirror switch and install switch into trim panel. (11) Install screws to attach accessary switch panel to door trim. (12) Install screw cover into switch panel. (13) If equipped, install window crank. (14) If equipped, install screws to attach trim panel to door inside map pocket. (15) If equipped, install screw to attach door pull cup to inner door panel. (16) If equipped, install screws to attach door assist handle to inner door panel. (17) Connect wire connector into courtesy lamp. (18) Install lamp in door trim. (19) Install switch bezel. WINDOW CRANK REMOVAL (1) Using a window crank removal tool, disengage clip attaching window crank to regulator shaft (Fig. 14). NOTE: Wrap a shop towel around the window crank to catch the clip when it springs out. (2) Pull window crank from regulator shaft. Fig. 14 WINDOW CRANK - TYPICAL 1 - WINDOW CRANK REMOVAL TOOL 2 - WINDOW CRANK INSTALLATION (1) Place the clip on to the window crank handle. (2) Position window crank to regulator shaft. (3) Push window crank onto regulator shaft to engage retaining clip. 23 - 22 DOOR - FRONT RS WINDOW REGULATOR REMOVAL (1) Remove the watershield. (Refer to 23 - BODY/ DOOR - FRONT/WATERSHIELD - REMOVAL) (2) Remove door glass retaining clips and secure the window in the up position using masking tape or equivalent (Fig. 15). (3) Disconnect wire connector from power window motor, if equipped. (4) Loosen screws attaching front and rear window guide rails to inner door panel (Fig. 16). (5) Remove screw heads on guide rails from key hole slots in inner door panel. (6) Loosen screws attaching regulator to inner door panel. (7) Remove regulator from inner door panel. (8) Extract rear guide rail through inner door panel rear access hole (Fig. 17). (9) Extract front guide rail through front access hole. Fig. 16 FRONT DOOR MANUAL WINDOW REGULATOR - TYPICAL 1 - FRONT DOOR 2 - MANUAL WINDOW REGULATOR 3 - GUIDE RAILS Fig. 17 FRONT DOOR POWER WINDOW - TYPICAL 1 - POWER WINDOW MOTOR 2 - FRONT DOOR 3 - GUIDE RAILS Fig. 15 FRONT DOOR GLASS CLIPS 1 2 3 4 5 - DOOR GLASS GLASS LIFT PLATE CLIP GUIDE RAIL REGULATOR LIFT PLATE INSTALLATION (1) Insert front guide rail through front access hole. (2) Insert rear guide rail through rear access hole. (3) Place window regulator in position on inner door panel. (4) Place screw heads on guide rails in position through key hole slots in inner door panel. (5) Tighten screws to attach front and rear guide rails to inner door panel. (6) Connect wire connector into power window motor, if equipped. (7) Install door glass. (8) Verify door glass alignment and operation. (9) Install sound shield and door trim panel. DOOR - FRONT RS EXTERIOR HANDLE REMOVAL (1) Roll door glass up. (2) Remove the watershield. (Refer to 23 - BODY/ DOOR - FRONT/WATERSHIELD - REMOVAL) (3) Through access hole at rear of inner door panel, disconnect Vehicle Theft Security System (VTSS) switch connector from door harness, if equipped. (4) Disengage push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if equipped. (5) Disengage clip holding door latch linkage to door latch (Fig. 12). (6) Remove latch linkage from latch. (7) Disengage clip holding door lock linkage to door latch. (8) Remove lock linkage from latch. (9) Remove nuts holding outside door handle to door outer panel. 23 - 23 (10) Remove outside door handle from vehicle. INSTALLATION If outside door handle replacement is necessary, transfer lock cylinder from the original handle to the new one. (1) Place outside door handle in position on vehicle. (2) Install nuts attaching outside door handle to door outer panel (Fig. 12). Tighten nuts to 6 N·m (50 in. lbs.). (3) Insert lock linkage into door latch. (4) Engage clip to hold door lock linkage to latch. (5) Insert latch linkage into door latch. (6) Engage clip to hold door latch linkage to latch. (7) Install push-in fasteners to hold VTSS switch harness to inner door reinforcement bar, if equipped. (8) Connect VTSS switch connector into door harness, if equipped. (9) Verify door latch operation. (10) Install sound shield and door trim panel. 23 - 24 DOORS - SLIDING RS DOORS - SLIDING TABLE OF CONTENTS page CENTER HINGE REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . SLIDING DOOR STOP BUMPER BEZEL REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . STOP BUMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . HOLD OPEN LATCH REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . HOLD OPEN LATCH STRIKER REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . LATCH / LOCK ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . CENTER STRIKER REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . LOWER HINGE REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . REAR LATCH STRIKER REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . SLIDING DOOR REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . ADJUSTMENTS SLIDING DOOR ADJUSTMENTS . . . . . . . . . . 24 . . . . . . . . 24 . . . . . . . . 25 . . . . . . . . 25 . . . . . . . . 25 . . . . . . . . 25 . . . . . . . . 25 . . . . . . . . 25 . . . . . . . . 26 . . . . . . . . 26 . . . . . . . . 26 . . . . . . . . 26 . . . . . . . . 27 . . . . . . . . 27 . . . . . . . . 28 . . . . . . . . 28 . . . . . . . . 28 . . . . . . . . 28 . . . . . . . . 29 . . . . . . . . 29 page STABILIZER REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . STABILIZER SOCKET REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . TRIM PANEL REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . INSIDE LATCH HANDLE REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . BELLCRANK REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . OUTSIDE HANDLE REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . UPPER HINGE REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . OUTSIDE HANDLE CABLE REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . INSIDE HANDLE CABLE REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . HOLD OPEN LATCH CABLE REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . . . 37 . . . . . . . . . . . . . . . . . 37 . . . . . . . . . . . . . . . . . 37 . . . . . . . . . . . . . . . . . 38 . . . . . . . . . . . . . . . . . 38 . . . . . . . . 30 CENTER HINGE REMOVAL NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Open sliding door to the mid point of its travel. (2) Support sliding door on a suitable lifting device. (3) Mark outline of center hinge of inner door panel to aid installation. (4) Remove bolts attaching center hinge to sliding door. (5) Remove center hinge from sliding door. (6) Roll center hinge to rear of roller channel. (7) Remove center hinge from vehicle. INSTALLATION NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. NOTE: Center hinge has an adjustable bolt for up/down alignment. (Refer to 23 - BODY/DOORS SLIDING/SLIDING DOOR - ADJUSTMENTS) (1) Place center hinge in position on vehicle. DOORS - SLIDING RS 23 - 25 CENTER HINGE (Continued) (2) Roll center hinge forward in roller channel. (3) Place center hinge in position on sliding door and align marks. (4) Install bolts attaching center hinge to sliding door. (5) Verify sliding door alignment and operation. SLIDING DOOR STOP BUMPER BEZEL REMOVAL (1) Using a trim stick (C-4755), disengage clips attaching door stop bumper bezel to the door trim panel. (2) Remove bezel from vehicle (Fig. 1). (3) Tighten screws attaching rear of stop bumper to door inner panel. (4) Install door stop bumper bezel. HOLD OPEN LATCH REMOVAL (1) Open sliding door. (2) Remove sliding door sill plate. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE REMOVAL) (3) Remove nuts attaching hold open latch to lower roller arm (Fig. 2). (4) Remove hold open latch from lower arm. (5) Disconnect cable from hold open latch. (6) Remove hold open latch from vehicle. Fig. 1 SLIDING DOOR STOP BUMPER 1 - DOOR STOP BUMPER 2 - DOOR STOP BUMPER BEZEL 3 - SLIDING DOOR INSTALLATION (1) Place door stop bumper bezel into position (Fig. 1). (2) Engage clips attaching door stop bumper bezel to the door trim panel. STOP BUMPER REMOVAL (1) Remove door stop bumper bezel. (2) Loosen screws attaching rear of stop bumper to door inner panel (Fig. 1). (3) Remove screw attaching front of door stop bumper to door inner panel. (4) Remove door stop bumper from vehicle. INSTALLATION (1) Place stop bumper in position on vehicle. (2) Install screw attaching front of stop bumper to door inner panel (Fig. 1). Fig. 2 SLIDING DOOR HOLD OPEN LATCH 1 - SLIDING DOOR HOLD OPEN LATCH - MANUAL DOOR 2 - LOWER ROLLER ARM INSTALLATION (1) Place hold open latch in position on vehicle. (2) Connect cable to hold open latch. (3) Place hold open latch in position on lower arm. (4) Install nuts attaching the hold open latch to lower roller arm. Tighten nuts to 5 N·m (45 in. lbs.) torque. (5) Install sliding door sill plate. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE INSTALLATION) (6) Verify sliding door operation. 23 - 26 DOORS - SLIDING RS HOLD OPEN LATCH STRIKER LATCH / LOCK ASSEMBLY REMOVAL REMOVAL NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Open sliding door, do not latch open. (2) Remove sliding door sill plate. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE REMOVAL) (3) Remove two bolts attaching sliding door hold open latch striker to door sill (Fig. 3). (4) Remove hold open latch striker from vehicle. (1) Remove sliding door trim panel. (Refer to 23 BODY/DOORS SLIDING/TRIM PANEL REMOVAL) (2) Remove sliding door stop bumper. (Refer to 23 BODY/DOORS - SLIDING/STOP BUMPER REMOVAL) (3) Peel watershield away from adhesive around perimeter of inner door panel. CAUTION: Replace the latch/lock control if any of the metal clips on the latch/lock control are bent or broken. DO NOT attempt to repair the clips to retain the links. Fig. 3 SLIDING DOOR HOLD OPEN LATCH STRIKER 1 2 3 4 - POWER DOOR LOWER TRACK POWER DOOR HOLDING STRIKER MANUAL DOOR HOLDING STRIKER MANUAL DOOR LOWER TRACK INSTALLATION NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Place hold open latch striker in position on vehicle. (2) Install two bolts attaching sliding door hold open latch striker to door sill. (3) Install sliding door sill plate. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE INSTALLATION) (4) Verify sliding door operation. (4) Disengage external cable from latch/lock assembly (Fig. 4). (5) Remove foam block. (6) Remove inside door handle assembly (Refer to 23 - BODY/DOORS - SLIDING/INSIDE LATCH HANDLE - REMOVAL). (7) Disengage inside cable from latch/lock assembly. (8) Disengage link from bellcrank. (9) Disengage hold open latch cable from lower hinge. (10) Remove bolts attaching latch/lock control to sliding door (Fig. 5). (11) If equipped, lower latch and disconnect wire connector from power door lock motor. (12) Remove latch/lock from door. INSTALLATION NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Position latch/lock locking lever in unlocked position. (2) Place latch/lock in position on door (Fig. 5). (3) If equipped, engage wire connector into power door lock motor (Fig. 4). (4) Insert bolt into slots in sliding door inner panel. (5) Tighten bolts attaching latch/lock assembly to sliding door. (6) Engage inside cable into latch/lock assembly. DOORS - SLIDING RS 23 - 27 LATCH / LOCK ASSEMBLY (Continued) (12) Engage clip to hold bellcrank link to latch/lock control. (13) Verify sliding door operation. (14) Install latch/lock cover. (15) Insure that enough adhesive remains to securely retain the watershield. Replace as necessary. (16) Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. (17) Install sliding door stop bumper.(Refer to 23 BODY/DOORS - SLIDING/STOP BUMPER INSTALLATION) (18) Install sliding door trim panel.(Refer to 23 BODY/DOORS - SLIDING/TRIM PANEL - INSTALLATION) Fig. 4 SLIDING DOOR LATCH/LOCK ASSEMBLY 1 - SLIDING DOOR 2 - LATCH LOCK ASSEMBLY CENTER STRIKER REMOVAL (1) Remove sliding door trim panel. (Refer to 23 BODY/DOORS SLIDING/TRIM PANEL REMOVAL) (2) Remove bolts attaching stop bumper. Remove stop bumper from door. (3) Remove screws attaching center striker assembly to door end frame (Fig. 6). (4) Remove center striker assembly from door through access hole. Fig. 5 REMOVING SLIDING DOOR LATCH/LOCK ASSEMBLY 1 2 3 4 - WIRE HARNESS LATCH/LOCK ASSEMBLY BELLCRANK LINK ROD LINK AND SLEEVE ASSEMBLY (7) Install inside door handle assembly (Refer to 23 - BODY/DOORS - SLIDING/INSIDE LATCH HANDLE - INSTALLATION). (8) Install foam block. (9) Engage external cable to latch/lock assembly. (10) Engage link rod to bellcrank. (11) Engage hold open latch cable from lower hinge. Fig. 6 SLIDING DOOR CENTER STRIKER ASSEMBLY 1 - STRIKER BOLT ASSEMBLY 2 - SLIDING DOOR INSTALLATION (1) Place center striker in position on door through access hole (Fig. 6). (2) Install screws to attach center striker to door end frame. 23 - 28 DOORS - SLIDING RS CENTER STRIKER (Continued) (3) Install bolts attaching stop bumper. (4) Install sliding door trim panel (Refer to 23 BODY/DOORS - SLIDING/TRIM PANEL - INSTALLATION). INSTALLATION LOWER HINGE (1) Place roller arm into position (Fig. 7). (2) Engage roller arm to lower channel. (3) Install roller arm to sliding door. (4) Install bolts attaching lower roller arm to sliding door. (5) Install hold open latch striker. (6) Install screws attaching open latch to lower roller arm. (7) Install sliding door sill plate. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE INSTALLATION) (8) Check sliding door for proper operation. REMOVAL NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Open sliding door. (2) Mark outline of roller arm on sliding door to aid installation (Fig. 7). (3) Remove sliding door sill plate. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE REMOVAL) (4) Remove screws attaching open latch to lower roller arm. (5) Remove open latch from lower arm. (6) Support sliding door on a suitable lifting device with a padded upper surface. The door must be moveable with lifting device in place. (7) Remove hold open latch striker. (8) Remove bolts attaching lower roller arm to sliding door. (9) Remove roller arm from sliding door. (10) Disengage roller arm from lower channel. (11) Remove roller arm from vehicle. NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. REAR LATCH STRIKER REMOVAL (1) Open sliding door. (2) Mark outline of striker on C-pillar door jamb face to aid installation. (3) Remove screws attaching striker to C-pillar (Fig. 8). (4) Remove striker from vehicle. Fig. 8 SLIDING DOOR LATCH STRIKER 1 - LATCH STRIKER 2 - SLIDING DOOR Fig. 7 SLIDING DOOR LOWER ROLLER ARM 1 - POWER LOWER ROLLER ARM 2 - MANUAL LOWER ROLLER ARM INSTALLATION (1) Place striker in position on vehicle. (2) Align striker to outline marks on C-pillar. (3) Install screws attaching striker to C-pillar. Tighten screws to 28 N·m (21 ft. lbs.) torque. (4) Verify sliding door alignment and operation. DOORS - SLIDING RS 23 - 29 SLIDING DOOR REMOVAL NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Apply masking tape to outside surface of quarter panel below the center roller channel, rearward of the door opening. (2) Release sliding door latch and open door. (3) Apply masking tape to door jamb area, rearward of the upper roller channel. (4) Remove screw attaching upper stop bumper to upper roller arm (Fig. 9). (5) Remove upper stop from upper roller arm. (6) Remove center stop from sliding door. (Refer to 23 - BODY/DOORS - SLIDING/STOP BUMPER REMOVAL) (7) Remove sliding door sill plate. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE REMOVAL) (8) Remove hold open latch striker (Refer to 23 BODY/DOORS - SLIDING/HOLD OPEN LATCH STRIKER - REMOVAL). (9) Open quarter glass. (10) Remove center roller channel end cover (Fig. 10). (11) Support sliding door on a suitable lifting device with a padded upper surface. The door must be moveable with lifting device in place. Fig. 9 SLIDING DOOR UPPER STOP 1 - UPPER STOP PLATE 2 - SLIDING DOOR 3 - UPPER SLIDING DOOR HINGE CAUTION: Do not allow the center hinge roller to contact the quarter glass. Glass can break. (12) Slide door rearward until the upper sliding door hinge roller disengages from the upper channel (Fig. 11). (13) Continue moving the door rearward until the lower rollers exit the lower track. (14) Continue moving door rearward till center hinge roller exits the channel (Fig. 12) (15) Remove sliding door from vehicle. INSTALLATION NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. Fig. 10 CENTER CHANNEL END COVER 1 - CENTER CHANNEL 2 - CENTER CHANNEL END COVER 3 - PLASTIC NUT (1) (2) move (3) ing. Place sliding door in position on lifting device. Engage center hinge roller into channel and door forward (Fig. 12). Position door rearward of the sliding door open- CAUTION: Do not allow the center hinge roller to contact the quarter glass. Glass can break. 23 - 30 DOORS - SLIDING RS SLIDING DOOR (Continued) (10) Install center stop on sliding door. (Refer to 23 - BODY/DOORS - SLIDING/STOP BUMPER INSTALLATION) (11) Place upper roller stop bumper in position on upper roller arm. (12) Install screw attaching upper roller arm stop bumper to upper roller arm (Fig. 9). (13) Remove masking tape from body surfaces. (14) Verify door operation and fit. Adjust as necessary. (Refer to 23 - BODY/DOORS - SLIDING/SLIDING DOOR - ADJUSTMENTS) ADJUSTMENTS SLIDING DOOR ADJUSTMENTS Fig. 11 SLIDING DOOR UPPER ROLLER 1 - SLIDING DOOR 2 - UPPER HINGE 3 - UPPER CHANNEL NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. PRELIMINARY CHECKS Fig. 12 SLIDING DOOR CENTER ROLLER 1 2 3 4 - SLIDING DOOR QUARTER GLASS CENTER HINGE ROLLERS CENTER HINGE (4) Engage the center hinge roller into the channel (Fig. 12). (5) Roll door forward until lower roller engage into rear of the track. (6) Engage the upper sliding door hinge into the upper channels (Fig. 11). (7) Install hold open latch striker(Refer to 23 BODY/DOORS - SLIDING/HOLD OPEN LATCH STRIKER - INSTALLATION). (8) Install sliding door sill plate. (9) Install center roller channel end cover (Fig. 10). (1) Close the sliding door, visually checking C-post striker alignment entry into latch. Striker at this point must not affect alignment. Striker should go straight into the latching mechanism. (2) On vehicles with left sliding doors, check the fuel door blocker striker entry into latch. Striker at this point must not affect alignment. (3) Check C-post and B-post for door to aperture gaps and door to door gaps. All gaps should be 5 mm ± 1 mm. (4) Check door for height using character lines as a reference. Also check roof contour as a controlling factor. Using the procedures noted below, adjust the side door in the order the individual steps are called out. DOOR FLUSHNESS ADJUSTMENT (1) Check sliding door flushness at the C-pillar striker. (2) Adjust the C-pillar striker in or out until the door is flush. (3) Check upper B-pillar flushness to A-pillar cover. (4) Loosen one nut on upper hinge and adjust door in or out until the door is flush. (5) Check flushness at upper C-pillar. (6) If upper C-pillar flushness is out of specification use a heavy rubber mallet on the door assembly until door is in specifications. DOOR GAP ADJUSTMENT - UP/DOWN (1) Visually inspect the sliding door for fitting low at the top of the door by checking the alignment of the top contour of the door to the quarter panel. DOORS - SLIDING RS 23 - 31 SLIDING DOOR (Continued) (2) Fully open the sliding door. (3) Verify that all center hinge bolts are tight. (4) Adjust the rear of the sliding door up by turning the center hinge bolt clockwise (Fig. 13). (5) Close the door and check the sliding door alignment. (6) Adjust the front of the sliding door up by adjusting lower hinge bolts. (7) Open door half way and remove lower hinge bolt access plug. (8) Loosen bolts as necessary to move the front of door up or down. (9) Check the upper hinge for possible bind, adjust as necessary. (10) Close the door and check the sliding door alignment. (11) Fully open door and apply thread lock nut onto the center hinge bolt. Tighten nut until till it butts up against the welded nut on the center hinge. Tighten nut to 15 N·m (130 in. lbs.). It may be necessary to hold the center hinge bolt to prevent it from turning while tightening nut. (12) Verify alignment, adjust as necessary. (d) Move hinge fore or aft to position the sliding door into the correct location. (e) Tighten center hinge bolts. (f) Verify alignmen, adjust as necessary. (3) If the sliding door is low at the B-post; (a) Remove access plug in the sliding door trim panel. (b) Open the door to mid-point of travel. (c) Mark outline of lower roller arm bracket on sliding door to assist in making adjustments. (d) Loosen lower roller arm bracket bolts (Fig. 14). (e) Move hinge downward to raise the door. (f) Tighten lower roller arm bracket bolts. (g) Verify alignment, adjust as necessary. Fig. 14 SLIDING DOOR LOWER ROLLER ARM 1 - LOWER ROLLER ARM BRACKET 2 - BOLTS 2 - SLIDING DOOR Fig. 13 SLIDING DOOR CENTER HINGE 1 - ADJUSTING BOLT 2 - WELD NUT DOOR GAP ADJUSTMENT - FORE/AFT (1) Check height of sliding door at the B-post and C-post to determine which area is contributing the greatest to the incorrect gaps. (2) If the sliding door is high at the C-post; (a) Open the door to mid-point of travel. (b) Mark outline of center hinge on sliding door to assist in making adjustments. (c) Loosen center hinge bolts (Fig. 13). (4) If the sliding door is low at the C-post; (a) Open the door to mid-point of travel. (b) Mark outline of center hinge on sliding door to assist in making adjustments. (c) Adjust the adjustment bolt up or down to move the door position. (Fig. 13). (d) Move hinge downward to raise the door. (e) Tighten center hinge bolts. (f) Verify alignment adjust as necessary. (5) If the sliding door is high at the B-post; (a) Remove access plug in the sliding door trim panel. (b) Open the door to mid-point of travel. (c) Mark outline of lower roller arm bracket on sliding door to assist in making adjustments. (d) Loosen lower roller arm bracket bolts (Fig. 14). (e) Move hinge upward to raise the door. (f) Tighten lower roller arm bracket bolts. (g) Verify alignment, adjust as necessary. 23 - 32 DOORS - SLIDING RS SLIDING DOOR (Continued) DOOR SEAL COMPRESSION (1) First check Gap & Flush (Refer to 23 - BODY/ BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS). Check seal compression near the middle of the door even with the latch assembly. Using a piece of paper, place it across door seal and close door. Pull paper out of door opening. If paper tears setting is to tight, if paper slides thought to easily the compression is insufficient and needs to be adjusted. (2) Adjust seal compression at the top of the B-post seal; (a) Open door to mid-point of travel. (b) Mark outline of upper roller arm on door to assist in making adjustments. (c) Loosen bolts attaching upper roller arm to door (Fig. 9). (d) Decrease the length of the upper roller arm to increase seal compression. (e) Increase the length of the upper roller arm to decrease seal compression. (f) Tighten all upper roller arm bolts. (g) Verify door alignment, adjust as necessary. (3) Adjust seal compression at the bottom of B-post seal. (a) Open door to mid-point of travel. (b) Mark outline of lower roller arm on lower roller arm bracket to assist in making adjustments (Fig. 15). (c) Loosen bolts holding lower roller arm to lower roller arm bracket. (d) Pivot lower roller arm toward center of vehicle to decrease seal compression. (e) Pivot lower roller arm outward to increase seal compression. (f) Tighten lower roller arm bolts. (g) Verify alignment, adjust as necessary. Fig. 15 Sliding Door Lower Roller Arm 1 - POWER LOWER ROLLER ARM 2 - MANUAL LOWER ROLLER ARM STABILIZER REMOVAL (1) Open sliding door. (2) Remove screws attaching stabilizer to door end frame (Fig. 16). (3) Remove stabilizer from vehicle. NOTE: Adjusting seal compression at the B-post can affect door flushness the C-post. STABILIZER ADJUSTMENT - UPPER/LOWER (1) Open sliding door. (2) Loosen the bolts holding the male stabilizers to the sliding door enough that the stabilizers can move with some effort. (3) Close and then reopen sliding door. (4) Tighten all stabilizers bolts. Fig. 16 SLIDING DOOR STABILIZER 1 - SLIDING DOOR 2 - STABILIZER INSTALLATION (1) Place stabilizer in position on vehicle. NOTE: Loose install screws first. Fit should be snug but free to move when closing door to align to body half stabilizer. DOORS - SLIDING RS 23 - 33 STABILIZER (Continued) (2) Install screws attaching stabilizer to door end frame. (3) Open door and final tighten screws. (4) Verify sliding door operation. STABILIZER SOCKET REMOVAL (1) Open sliding door. (2) Remove screws holding stabilizer socket to B-pillar (Fig. 17). (3) Remove stabilizer socket from vehicle. Fig. 18 SLIDING DOOR TRIM PANEL 1 2 3 4 5 6 - PUSH-IN FASTENERS SLIDING DOOR UPPER FRAME MOLDING SLIDING DOOR TRIM PANEL PUSH-IN FASTENERS PUSH-IN FASTENERS SLIDING DOOR INSTALLATION (1) Place stabilizer socket in position on vehicle. (2) Install screws to hold stabilizer socket to B-pillar. Tighten nuts to 5 N·m (45 in. lbs.) torque. (3) Close sliding door and verify operation. (1) Place sliding door trim panel in position on vehicle. (2) Align locating pins on backside of trim panel to mating holes in the inner door panel. (3) Engage push-in fasteners to hold trim to door panel around perimeter and upper edge of door (Fig. 18). (4) Install pull cup screw. (5) If necessary, install screw from inside ash receiver bezel on left sliding door trim panel. (6) Install sliding door upper frame molding. TRIM PANEL INSIDE LATCH HANDLE REMOVAL REMOVAL (1) Remove sliding door upper frame molding. (2) If removing the left sliding door trim panel, remove screw from inside ash receiver bezel. (3) Remove screw from pull cup. (4) Disengage push-in fasteners holding trim to door panel around perimeter and upper edge of door (Fig. 18). (5) Remove sliding door trim panel from vehicle. (1) Remove sliding door trim panel. (Refer to 23 BODY/DOORS SLIDING/TRIM PANEL REMOVAL) (2) Remove screws attaching bottom of inside latch handle to sliding door (Fig. 19). (3) Remove two screw attaching top of inside latch handle to sliding door. (4) Remove latch handle from sliding door. Fig. 17 SLIDING DOOR STABILIZER SOCKET 1 - B-PILLAR 2 - STABILIZER SOCKET INSTALLATION 23 - 34 DOORS - SLIDING RS INSIDE LATCH HANDLE (Continued) (5) Disengage cable end from clip on release handle mechanism. (6) Disengage cable end from release handle mechanism. (7) Remove push pin fastener attaching cable end to release handle. (8) Disengage cable casing end from release handle (Fig. 20). (9) Disengage cable end from latch handle. (10) Remove handle from vehicle. INSTALLATION (1) Place inside latch handle in position on vehicle. (2) Engage cable end into latch handle. (3) Engage cable casing end into release handle. (4) Install push pin fastener to hold cable into release handle. (5) Engage cable end into release handle mechanism. (6) Engage clip to hold cable end into release handle mechanism. (7) Place latch handle in position on sliding door. (8) Install screw to hold top of inside release handle to sliding door. (9) Install screws to hold bottom of inside latch handle to sliding door. (10) Verify sliding door operation. Adjust as necessary. (Refer to 23 - BODY/DOORS - SLIDING/SLIDING DOOR - ADJUSTMENTS) (11) Install sliding door trim panel.(Refer to 23 BODY/DOORS - SLIDING/TRIM PANEL - INSTALLATION) BELLCRANK REMOVAL Fig. 19 SLIDING DOOR INSIDE HANDLE 1 2 3 4 - INSIDE ASSIST HANDLE SLIDING DOOR LATCH BELLCRANK INSIDE RELEASE HANDLE CABLE (1) Remove stop bumper (Refer to 23 - BODY/ DOORS - SLIDING/STOP BUMPER - REMOVAL). (2) Remove sliding door trim panel. (Refer to 23 BODY/DOORS SLIDING/TRIM PANEL REMOVAL) (3) Peel watershield away from adhesive around perimeter of inner door panel as necessary to gain access to latch bellcrank. (4) Disengage key cylinder link (Fig. 21). (5) Disengage lock link. (6) Disengage link and sleeve (7) Remove bellcrank by rotating bellcrank to release it from door. (8) Remove bellcrank from vehicle. INSTALLATION Fig. 20 RELEASE HANDLE CABLE 1 - ASSIST HANDLE MECHANISM 2 - SLIDING DOOR INSIDE ASSIST HANDLE 3 - RELEASE HANDLE CABLE (1) Position bellcrank on vehicle. (2) Rotate bellcrank into position. (3) Place lock link into position and engage clip (Fig. 21). (4) Place link and sleeve into position and engage clip. (5) Place key cylinder link into position and engage clip. (6) Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. (7) Install sliding door trim panel (Refer to 23 BODY/DOORS - SLIDING/TRIM PANEL - INSTALLATION). DOORS - SLIDING RS 23 - 35 BELLCRANK (Continued) Fig. 21 BELLCRANK 1 2 3 4 5 - LOCK LINK LATCH LINK LINK AND SLEEVE - OUTSIDE HANDLE BELLCRANK KEY CYLINDER LINK (8) Install stop bumper (Refer to 23 - BODY/ DOORS - SLIDING/STOP BUMPER - INSTALLATION). Fig. 22 SLIDING DOOR OUTSIDE LATCH RELEASE HANDLE 1 2 3 4 5 6 7 - OUTSIDE DOOR PANEL LOCK LINK LATCH LINK LOCKING LINK AND SLEEVE LINK BELLCRANK KEY CYLINDER LOCK LINK KEY CYLINDER INSTALLATION OUTSIDE HANDLE REMOVAL (1) Remove sliding door trim panel. (Refer to 23 BODY/DOORS SLIDING/TRIM PANEL REMOVAL) (2) Remove sliding door stop bumper. (Refer to 23 BODY/DOORS - SLIDING/STOP BUMPER REMOVAL) (3) Peel watershield away from adhesive around perimeter of inner door panel as necessary to access outside release handle fasteners. (4) Disengage clip attaching outside door handle linkage to door cable. (5) Remove linkage from outside door handle. (6) Remove three nuts attaching outside door handle to outer door panel (Fig. 22). (7) Remove outside door handle from vehicle. (1) Position outside door handle on vehicle. (2) Install nuts attaching outside door handle to outer door panel. (3) Engage clip attaching linkage to outside door handle. (4) Engage rigging cam to latch/lock control mechanism. (5) Move clip on latch/lock control to bottom of slot and engage linkage to latch/lock control. (6) Verify sliding door operation. Adjust as necessary. (7) Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. (8) Install sliding door stop bumper. (Refer to 23 BODY/DOORS - SLIDING/STOP BUMPER INSTALLATION) (9) Install sliding door trim panel. (Refer to 23 BODY/DOORS - SLIDING/TRIM PANEL - INSTALLATION) 23 - 36 DOORS - SLIDING RS UPPER HINGE REMOVAL (1) Open sliding door, do not latch open. (2) Remove screw attaching upper stop bracket to upper roller bracket (Fig. 23). (3) Remove stop bracket from vehicle. (4) Place a padded block between the open sliding door and the roof rail. (5) Mark outline of upper hinge bracket on sliding door. (6) Remove bolts attaching upper roller to sliding door (Fig. 24). (7) Remove upper hinge from door. (8) Slide roller out of rear end of roof upper channel. (9) Remove upper hinge from vehicle. Fig. 24 SLIDING DOOR UPPER HINGE 1 - SLIDING DOOR UPPER HINGE 2 - SLIDING DOOR OUTSIDE HANDLE CABLE REMOVAL NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. Fig. 23 SLIDING DOOR UPPER STOP 1 - UPPER STOP PLATE 2 - SLIDING DOOR 3 - UPPER SLIDING DOOR HINGE INSTALLATION (1) Place upper hinge in position on vehicle (Fig. 24). (2) Slide roller into rear end of roof upper channel. (3) Place upper hinge in position on door. (4) Align outline marks on sliding door to upper roller bracket (5) Install bolts attaching upper hinge to sliding door. (6) Remove padded block from between sliding door and roof rail. (7) Place stop bracket in position on vehicle. (8) Install screw attaching upper stop bracket to upper roller bracket (Fig. 23). (9) Verify sliding door alignment and operation. Adjust as necessary. (Refer to 23 - BODY/DOORS SLIDING/SLIDING DOOR - ADJUSTMENTS) (1) Disconnect and isolate the negative battery cable. (2) Remove stop bumper (Refer to 23 - BODY/ DOORS - SLIDING/STOP BUMPER - REMOVAL). (3) Remove the appropriate side door trim panel. (Refer to 23 - BODY/DOORS - SLIDING/TRIM PANEL - REMOVAL) (4) Peel watershield away from adhesive around perimeter of inner door panel. CAUTION: Make note of cable routing and foam insulator placement. This will prove helpful when reinstalling replacement cable. Be certain replacement cable is routed and retained correctly. (5) Trace the outside handle cable along its routing path and disconnect from its retaining clips. (6) Disconnect the outside handle cable from the latch assembly. Gently pry cable sleeve retainer out of the latch mounting bracket and then unhook swedged cable end from the latch link. (7) Disconnect the outside handle cable from the handle assembly. Gently pry cable sleeve retainer out of the handle bracket and then unhook swedged cable end from the handle link. (8) Remove the outside handle cable from the side door. DOORS - SLIDING RS 23 - 37 OUTSIDE HANDLE CABLE (Continued) INSTALLATION NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Match the replacement cable up against the old cable to verify the correct part. (2) Position the outside handle cable on the side door. (3) Connect the outside handle cable on the handle assembly. Hook the swedged cable end on the handle link and gently push the cable sleeve retainer in the handle bracket. NOTE: The outside handle cable is marked with red tape. It must be attached to the latch at the lowest point. This is marked with a “R” on the latch. (4) Connect the outside handle cable on the latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. (5) Trace the outside handle cable along its routing path and install on its retaining clips and position foam insulators. Use previously made schematic as a guide or remove the opposite side door trim panel and use that door as a guide. CAUTION: Be certain replacement cable is routed and retained correctly and foam insulators are properly positioned. (6) Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. (7) Install the appropriate side door trim panel on the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/ TRIM PANEL - INSTALLATION) (8) Install stop bumper (Refer to 23 - BODY/ DOORS - SLIDING/STOP BUMPER - INSTALLATION). (9) Connect the negative battery cable. INSIDE HANDLE CABLE REMOVAL NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Disconnect and isolate the negative battery cable. (2) Remove the appropriate side door trim panel from the vehicle. (Refer to 23 - BODY/DOORS SLIDING/TRIM PANEL - REMOVAL) (3) Peel watershield away from adhesive around perimeter of inner door panel. (4) Remove the inside handle assembly from the side door. (Refer to 23 - BODY/DOORS - SLIDING/ INSIDE LATCH HANDLE - REMOVAL) (5) Disconnect the inside handle cable from the handle assembly. Gently pry cable sleeve retainer out of the handle bracket and then unhook swedged cable end from the handle link. (6) Open the side door and remove the latch assembly. Refer to the Power Side Doors section for the procedure. CAUTION: Make note of cable routing and foam insulator placement. This will prove helpful when reinstalling replacement cable. Be certain replacement cable is routed and retained correctly. (7) Trace the inside handle cable along its routing path and disconnect from its retaining clips. (8) Disconnect the inside handle cable from the latch assembly. Gently pry cable sleeve retainer out of the latch mounting bracket and then unhook swedged cable end from the latch link. (9) Remove the inside handle cable from the side door. INSTALLATION NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Match the replacement cable up against the old cable to verify the correct part. (2) Position the inside handle cable on the side door. (3) Connect the inside handle cable on the handle assembly. Hook the swedged cable end on the handle link and gently push the cable sleeve retainer in the handle bracket. (4) Install the inside handle assembly on the side door. (Refer to 23 - BODY/DOORS - SLIDING/INSIDE LATCH HANDLE - INSTALLATION) NOTE: The inside handle cable is marked with blue tape and must be attached to the latch at the center (just above the lower cable). This position is marked with a “B” on the latch. (5) Connect the inside handle cable on the latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. 23 - 38 DOORS - SLIDING RS INSIDE HANDLE CABLE (Continued) (6) Trace the inside handle cable along its routing path and install on its retaining clips and position foam insulators. Use previously made schematic as a guide or remove the opposite side door trim panel and use that door as a guide. of the handle bracket and then unhook swedged cable end from the latch link. (9) Remove the hold open latch cable from the side door. INSTALLATION CAUTION: Be certain replacement cable is routed and retained correctly and foam insulators are properly positioned. (7) Install the latch assembly. Refer to the Power Side Doors section for the procedure. (8) Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. (9) Install the appropriate side door trim panel on the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/ TRIM PANEL - INSTALLATION) (10) Connect the negative battery cable. HOLD OPEN LATCH CABLE REMOVAL NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Disconnect and isolate the negative battery cable. (2) Remove the appropriate side door trim panel from the vehicle. (Refer to 23 - BODY/DOORS SLIDING/TRIM PANEL - REMOVAL) (3) Peel watershield away from adhesive around perimeter of inner door panel. (4) Open the side door and remove the latch assembly. (Refer to 8 - ELECTRICAL/POWER DOORS/LATCH - REMOVAL) CAUTION: Make note of cable routing and foam insulator placement. This will prove helpful when reinstalling replacement cable. Be certain replacement cable is routed and retained correctly. (5) Trace the hold open latch cable along its routing path and disconnect from its retaining clips. (6) Disconnect the hold open latch cable from the latch assembly. Gently pry cable sleeve retainer out of the latch mounting bracket and then unhook swedged cable end from the latch link. (7) Remove the hold open latch from the side door. (Refer to 23 - BODY/DOORS - SLIDING/HOLD OPEN LATCH - REMOVAL) (8) Disconnect the hold open latch cable from the hold open latch. Gently pry cable sleeve retainer out NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section. (1) Match the replacement cable up against the old cable to verify the correct part. (2) Position the hold open latch cable on the side door. NOTE: The hold open latch cable is marked with white tape. It must be attached to the upper most cable attachment at the latch. This position is marked with a “W” on the latch. (3) Connect the hold open latch cable on the hold open latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. (4) Install the hold open latch on the side door.(Refer to 23 - BODY/DOORS - SLIDING/HOLD OPEN LATCH - INSTALLATION) (5) Connect the hold open latch cable on the latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. (6) Trace the outside handle cable along its routing path and install on its retaining clips and position foam insulators. Use previously made schematic as a guide or remove the opposite side door trim panel and use that door as a guide. CAUTION: Be certain replacement cable is routed and retained correctly and foam insulators are properly positioned. (7) Install the latch assembly. (Refer to 8 - ELECTRICAL/POWER DOORS/LATCH - INSTALLATION) (8) Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. (9) Install the appropriate side door trim panel on the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/ TRIM PANEL - INSTALLATION) (10) Connect the negative battery cable. DECKLID/HATCH/LIFTGATE/TAILGATE RS 23 - 39 DECKLID/HATCH/LIFTGATE/TAILGATE TABLE OF CONTENTS page EXTERIOR HANDLE REMOVAL . . . . . . INSTALLATION . . HINGE REMOVAL . . . . . . INSTALLATION . . LATCH REMOVAL . . . . . . INSTALLATION . . LATCH STRIKER REMOVAL . . . . . . INSTALLATION . . LIFTGATE REMOVAL . . . . . . INSTALLATION . . LIFTGATE SPOILER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . . . . . . . . . . . . . . . . . 41 page INSTALLATION . . . . . . . . . . . . . . . LOCK CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . SUPPORT CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . TRIM PANEL REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . SLAM BUMPER REMOVAL REMOVAL . . . . . . . . . . . . . . . . . REMOVAL - LIFTGATE SIDE . . . INSTALLATION INSTALLATION . . . . . . . . . . . . . INSTALLATION - LIFTGATE SIDE . . . . . . . . . . 41 . . . . . . . . . . 42 . . . . . . . . . . 42 . . . . . . . . . . 42 . . . . . . . . . . 42 . . . . . . . . . . 42 . . . . . . . . . . 43 . . . . . . . . . . 43 . . . . . . . . . . 43 . . . . . . . . . . 43 . . . . . . . . . 43 EXTERIOR HANDLE HINGE REMOVAL REMOVAL (1) Remove liftgate trim panel. (Refer to 23 BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/ TRIM PANEL - REMOVAL) (2) Disconnect the exterior handle electrical connectors. (3) Remove the two outer screws and the two inner screws. (4) Remove the exterior handle/license plate light assembly. (1) Release liftgate latch and open liftgate. (2) Support liftgate on a suitable lifting device in the full open position. (3) Apply several layers of duct tape on the outside of to roof across the gap to the lift gate to hold the liftgate in position. (4) Remove bolts attaching liftgate hinge to roof header. (5) Disconnect VTSS switch from the body harness. (6) Remove bolts attaching hinge to liftgate (Fig. 1). (7) Remove hinge from vehicle. INSTALLATION (1) Route the exterior handle electrical connector through the door and position handle. (2) Install the two out screws and tighten to 20 N·m (15 ft. lbs.). (3) Install the two inner bolts and tighten to 40 N·m (30 ft. lbs.). (4) Connect the electrical connector. (5) Install the trim panel. (Refer to 23 - BODY/ DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM PANEL - INSTALLATION) INSTALLATION (1) If necessary, paint replacement hinge before installation. (2) Place hinge in position on vehicle. (3) Align hinge to marks on liftgate. (4) Install bolts attaching hinge to liftgate (Fig. 1) . Tighten bolts to 33 N·m (24 ft. lbs.) torque. 23 - 40 DECKLID/HATCH/LIFTGATE/TAILGATE RS HINGE (Continued) Fig. 1 LIFTGATE HINGE 1 - LIFTGATE 2 - HINGE 3 - REAR ROOF HEADER (5) Align hinge to marks on roof header. (6) Install bolts attaching liftgate hinge to roof header. Tighten outer two bolts to 33 N·m (24 ft. lbs.) torque. The sheet medal screw at center 12 N·m (105 in. lbs.) (7) Remove duct tape from roof and liftgate. (8) Verify liftgate alignment. Refer to Liftgate Remove and Installation for proper gap measurements. LATCH REMOVAL (1) Remove liftgate trim panel. (2) Disengage outside handle link from clip on latch. (3) Disconnect wire connector from liftgate latch (Fig. 2). (4) Remove screws attaching latch to liftgate. (5) Remove latch from vehicle. INSTALLATION (1) Engage link and place latch in position on vehicle. (2) Install screws attaching latch to liftgate. Tighten to 10 N·m (95 lb.in.) torque. (3) Connect wire connector to liftgate latch. (4) Verify liftgate fit and operation. Adjust as necessary. (5) Install liftgate trim panel. Fig. 2 LIFTGATE LATCH 1 2 3 4 5 - ELECTRICAL CONNECTOR LIFTGATE LATCH SCREW LIFTGATE LIFTGATE LOCK CYLINDER LATCH STRIKER REMOVAL (1) (2) tion. (3) (4) Open liftgate. Mark outline of striker on sill to aid installaRemove screws attaching striker to sill (Fig. 3). Remove striker from vehicle. INSTALLATION (1) Place striker in position on vehicle. (2) Align striker to outline mark on sill. (3) Install screws attaching striker to sill. Tighten screws to 28 N·m (21 ft. lbs.) torque. (4) Verify liftgate alignment and operation. LIFTGATE REMOVAL (1) Release liftgate latch and open liftgate. (2) Remove screws attaching liftgate wire connector to rear header. (3) Disconnect liftgate wire harness from body wire harness. (4) Remove liftgate upper frame molding. DECKLID/HATCH/LIFTGATE/TAILGATE RS 23 - 41 LIFTGATE (Continued) Fig. 3 LIFTGATE LATCH STRIKER 1 - LIFTGATE SILL 2 - LIFTGATE STRIKER (5) Disconnect rear window washer hose from spray nozzle. (6) Support liftgate on a suitable lifting device. (7) Remove screws attaching support cylinders to liftgate. (8) Remove bolts attaching liftgate hinge to roof header (Fig. 4). (9) With assistance, remove liftgate from vehicle. (3) Install screws attaching support cylinders to liftgate. Tighten bolts to 28 N·m (21 ft. lbs.) torque. (4) Remove lifting device from under liftgate. (5) Connect liftgate wire harness into body wire harness. (6) Install screws attaching wire connector to rear header. (7) Connect rear window washer hose onto spray nozzle. (8) Install liftgate upper frame molding. (9) Verify liftgate alignment. The liftgate should have a gap to adjacent panels and fit flush across the gaps. The gap is; • 7 mm (0.280 in.) to the fascia, • 6 mm (0.240 in.) to the roof, • 4 mm (0.160 in.) to the aperture. LIFTGATE SPOILER REMOVAL (1) Remove nuts (Fig. 5). (2) Remove spoiler from vehicle. Fig. 5 LIFTGATE SPOILER Fig. 4 LIFTGATE 1 - HINGE 2 - ROOF 3 - NET HOLE OR SLOT INSTALLATION (1) With assistance, place liftgate in position on vehicle. (2) Install bolts attaching liftgate hinge to roof header. Tighten bolts to 33 N·m (24 ft. lbs.) torque. 1 - RETAINER SEALER WASHER 2 - LIFT GATE SPOILER INSTALLATION (1) Place liftgate spoiler in position and install nuts. (2) Tighten nuts to 9 N·m (80 in. lbs.) torque. 23 - 42 DECKLID/HATCH/LIFTGATE/TAILGATE RS LOCK CYLINDER REMOVAL (1) Remove the liftgate trim panel. (Refer to 23 BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/ TRIM PANEL - REMOVAL) (2) Disconnect the electrical connector. (3) Disconnect the latch rod. (4) Rotate plastic lock cylinder nut one quarter turn and remove nut and spring washer. (5) Remove the lock cylinder from the liftgate. INSTALLATION (1) Install lock cylinder into liftgate. (2) Install the plastic lock cylinder lock nut, spring washer and rotate one quarter turn. (3) Connect the electrical connector. (4) Connect the latch rod. (5) Install the trim panel. (Refer to 23 - BODY/ DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM PANEL - INSTALLATION) (6) Verify lock cylinder operation. SUPPORT CYLINDER REMOVAL (1) Release liftgate latch and open liftgate. (2) Support liftgate on a suitable lifting device in the full open position. (3) Pull liftgate opening weatherstrip from D-pillar flange next to prop assembly end pivot. (4) Remove bolt attaching end pivot to D-pillar (Fig. 6). (5) Remove bolt attaching prop assembly to liftgate. (6) Remove prop assembly from vehicle. Fig. 6 LIFTGATE PROP ASSEMBLY 1 - LIFTGATE 2 - PROP ASSEMBLY TRIM PANEL REMOVAL (1) Remove the bolt attaching the lift motor link, if equipped (Fig. 7). (2) Remove liftgate upper frame molding (Fig. 8). (3) Remove assist handle screws. (4) Disengage hidden clips holding trim panel to liftgate from around perimeter or liftgate (Fig. 8). (5) Disconnect wire connector from lamps. (6) Remove liftgate trim panel from vehicle. INSTALLATION Ensure that the cylinder end is attached to the D-pillar and the shaft end is attached to the liftgate. (1) Place prop assembly in position. (2) Install bolt attaching prop assembly to liftgate. (3) Install bolt attaching end pivot to D-pillar. Tighten bolts to 28 N·m (21 ft. lbs.) torque. (4) Install liftgate opening weatherstrip to D-pillar flange next to prop assembly end pivot. (5) Close liftgate. Check liftgate operation. Fig. 7 LIFTGATE MOTOR 1 - LIFTGATE MOTOR LINK BOLT 2 - LIFTGATE MOTOR 3 - LIFTGATE DECKLID/HATCH/LIFTGATE/TAILGATE RS 23 - 43 TRIM PANEL (Continued) Fig. 8 LIFTGATE TRIM 1 2 3 4 5 - LIFTGATE - LOWER TRIM PANEL - ASSIST HANDLE SCREWS - UPPER TRIM - UPPER TRIM CLIPS Fig. 9 LIFTGATE STOP BUMPER - BODY SIDE 1 - LIFTGATE STOP BUMPER 2 - LIFTGATE OPENING INSTALLATION (1) Place liftgate trim panel in position on vehicle. (2) Engage hidden clips to hold trim panel to liftgate and fasteners around perimeter of liftgate (Fig. 8). (3) Connect wire connector into lamp. (4) Install courtesy lamps into liftgate trim. (5) Install screws to hold assist handle to liftgate. (6) Install upper frame side moldings. (7) Install liftgate upper frame molding. (8) Install the bolt attaching the lifgate motor link and tighten to 28 N·m (21 ft. lbs.) SLAM BUMPER Fig. 10 LIFTGATE STOP BUMPER - LIFTGATE SIDE 1 - LIFTGATE STOP BUMPER 2 - LIFTGATE REMOVAL REMOVAL (1) Open liftgate. (2) Remove liftgate stop bumper body side attaching bolts (Fig. 9). (3) Remove liftgate stop bumper. REMOVAL - LIFTGATE SIDE (1) Open liftgate. (2) Remove liftgate stop bumper liftgate side attaching bolts (Fig. 10). (3) Remove liftgate stop bumper. INSTALLATION INSTALLATION (1) (2) body (3) Place liftgate stop bumper into position. Install bolts attaching liftgate stop bumper to side (Fig. 9). Close liftgate. INSTALLATION - LIFTGATE SIDE (1) Place liftgate stop bumper into position. (2) Install bolts attaching liftgate stop bumper to liftgate (Fig. 10). (3) Close liftgate. 23 - 44 EXTERIOR RS EXTERIOR TABLE OF CONTENTS page BODY SIDE MOLDINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . COWL GRILLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . EXTERIOR NAME PLATES - TAPE ATTACHED REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . EXTERIOR NAME PLATES - ADHESIVE ATTACHED REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . FRONT FENDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . FUEL FILL DOOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . FUEL FILL DOOR BLOCKER LATCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . FUEL FILL DOOR BLOCKER LATCH STRIKER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . FUEL FILL DOOR BLOCKER LOCKOUT LINK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 . . . 45 . . . 50 . . . 50 . . . 50 . . . 51 . . . 51 . . . 51 . . . 51 . . . 51 . . . 52 . . . 52 . . . 52 . . . 52 . . . 53 . . . 53 . . . 53 BODY SIDE MOLDINGS REMOVAL Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig. 5)for proper location of fasteners holding the molding to the wheelhouse lip and rocker panels. (1) Warm the affected stick on molding and body metal to approximately 38° C (100° F) using a suitable heat lamp or heat gun. page INSTALLATION . . . . . . . . . . . . . . . . . . GRILLE OPENING REINFORCEMENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . FRONT WHEELHOUSE SPLASH SHIELD REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . LUGGAGE RACK RISER REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . LUGGAGE RACK CROSSBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . REAR QUARTER PANEL/FENDER AIR EXHAUSTER DESCRIPTION . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . ROOF JOINT MOLDING REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . SIDE VIEW MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . SIDE VIEW MIRROR GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . . . 54 . . . . . . . 54 . . . . . . . 55 . . . . . . . 55 . . . . . . . 55 . . . . . . . 56 . . . . . . . 56 . . . . . . . 57 . . . . . . . 57 . . . . . . . 57 . . . . . . . 58 . . . . . . . 58 . . . . . . . 58 . . . . . . . 58 . . . . . . . 58 . . . . . . . 59 . . . . . . . 59 (2) If equipped, remove pop rivets holding molding edge to wheelhouse lip. (3) Pull stick on molding from painted surface. (4) Remove adhesive tape residue from painted surface of vehicle. Use a 3M Scotch-Brite™ Molding Adhesive and Stripe Removal Disc, or equivalent, to clean adhesive residue from painted surfaces. These products are available from automotive paint suppliers. Refer to instructions supplied with the specific product for proper usage. EXTERIOR RS 23 - 45 BODY SIDE MOLDINGS (Continued) Fig. 1 BODY SIDE MOLDINGS - BASE TYPICAL 1 - GUIDE PINS 2 - FRONT DOOR MOLDING INSTALLATION Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig. 5)for proper location of fasteners to hold the molding to the wheelhouse lip and rocker panels. (1) If molding is to be reused; (a) Remove tape residue from molding. (b) Clean back of molding with Mopart Super Kleen, or equivalent. (c) Wipe molding dry with lint free cloth. (d) Apply a single coat of Mopart TPO Molding Prep to tape side of molding and allow to dry thoroughly. (e) Apply new body side molding (two sided adhesive) tape to back of molding. 3 - SLIDING DOOR MOLDING 4 - QUARTER PANEL MOLDING (2) Clean body surface with Mopart Super Kleen, or equivalent. Wipe surface dry with lint free cloth. (3) Remove protective cover from tape on back of molding. (4) Apply molding to body from front to rear, inserting locator pins into hole in body panel. (5) Using a roller tool, roll molding onto body panel with enough force to assure adhesion. Do not apply excessive force, or damage to body panels may result. (6) Install pop rivets to hold molding edge to wheelhouse lip, if necessary. 23 - 46 EXTERIOR RS BODY SIDE MOLDINGS (Continued) Fig. 2 BODY SIDE MOLDINGS - HIGHLINE TYPICAL 1 2 3 4 5 6 - QUARTER PANEL FRONT FENDER POP-RIVET FENDER MOLDING FRONT DOOR MOLDING SLIDING DOOR MOLDING 7 - GUIDE PINS 8 - QUARTER PANEL MOLDING 9 - LIFTGATE MOLDING 10 - POP-RIVET EXTERIOR RS BODY SIDE MOLDINGS (Continued) Fig. 3 BODY SIDE MOLDINGS - PREMIUM TYPICAL 1 2 3 4 5 6 - QUARTER PANEL FRONT FENDER POP-RIVET FENDER MOLDING POP-RIVET FASCIA 7 - FRONT DOOR MOLDING 8 - SLIDING DOOR MOLDING 9 - QUARTER PANEL MOLDING 10 - FASCIA MOLDING 11 - POP-RIVET 23 - 47 23 - 48 EXTERIOR RS BODY SIDE MOLDINGS (Continued) Fig. 4 BODY SIDE MOLDINGS - PREMIUM TYPICAL 1 2 3 4 5 6 - QUARTER PANEL FRONT FENDER POP-RIVET FENDER MOLDING POP-RIVET FASCIA 7 - FRONT DOOR MOLDING 8 - SLIDING DOOR MOLDING 9 - QUARTER PANEL MOLDING 10 - FASCIA MOLDING 11 - POP-RIVET EXTERIOR RS BODY SIDE MOLDINGS (Continued) Fig. 5 BODY SIDE MOLDINGS WITH APPLIQUE - TYPICAL 1 2 3 4 - FRONT ROCKER PANEL APPLIQUE FRONT DOOR MOLDING SLIDING DOOR MOLDING REAR ROCKER PANEL APPLIQUE 5 - LIFTGATE MOLDING 6 - POP-RIVET 23 - 49 23 - 50 EXTERIOR RS COWL GRILLE REMOVAL (1) Remove wiper arms. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER ARMS REMOVAL) (2) Remove four (4) screws securing cowl cover to wiper module (Fig. 6). (3) Disengage quarter turn fasteners at outboard ends of cowl grill from body. (4) Release hood latch and open hood. CAUTION: To prevent hood scratching of cowl grille before removal, cover outboard exterior ends of cowl grille with masking tape or equivalent method. NOTE: Do not over bend cowl grille during removal. Bend cowl grille just enough to clear top of wiper pivot shaft and bottom rear corner of hood. (5) Remove cowl grill by raising above driver side wiper pivot shaft and swinging away towards engine compartment. The cowl grille will need to be bent on outboard end to clear simultaneously top of wiper pivot shaft and bottom corner of hood. (6) Close hood. Do not latch. Remove outboard screws. (Fig. 7). (7) Disconnect washer hose in line connector. (8) Disconnect washer hose and grommet from hole in wiper module and pull out. (9) Remove cowl grille by raising over opposite wiper pivot shaft and removing away from vehicle. (10) Remove cowl cover from vehicle. Fig. 7 COWL COVER RETAINERS 1 2 3 4 - SCREW WINDSHIELD COWL COVER FRONT FENDER INSTALLATION (1) Reverse removal procedure. (2) When installing cowl cover over wiper module, make sure fore aft locator on the underside of cowl grill seat into the locator grooves on top of wiper module. (3) Star all cowl grille mounting screws by hand before torquing to specifications. (4) Assure washer hose is properly routed and not pinched. (5) Center cowl grille to body and windshield. (6) Assure “arrow” indicator head of quarter turn fasteners is pointing toward windshield. (7) Tighten screw to 1.2 N·m (11 in. lbs.) torque. (8) Install the wiper arms. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER ARMS - INSTALLATION) (9) Check for proper spray pattern from washer nozzles. EXTERIOR NAME PLATES TAPE ATTACHED Fig. 6 COWL COVER 1 2 3 4 - COWL COVER WIPER PIVOT WASHER HOSES HOOD REMOVAL (1) Mark reference points before removing. (2) Using a heat gun gently apply heat in a circular motion to loosen the adhesive bond. (3) Using a nonmetallic prying device, such as a plastic or wood trim stick gently pry up at corners and remove. EXTERIOR RS 23 - 51 EXTERIOR NAME PLATES - TAPE ATTACHED (Continued) (4) Clean off all traces of adhesive or double sided tape from the panel with a general purpose adhesive remover. FRONT FENDER INSTALLATION (1) Remove headlamp housing. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - REMOVAL) (2) Remove mud guard. (3) Remove inner splash shield. (4) Remove fender to fascia nuts. (5) Remove outboard cowl grille/fender bracket screw. (6) Remove fender bolt to lower rocker panel. (7) Remove fender bolt to lower cowl. (8) Pull fascia away from fender. (9) Remove bolts attaching fender to upper rail. (10) Remove fender from vehicle (Fig. 8). (1) (2) (3) tact (4) Clean panel surface with isopropy alcohol. Align badgeing to reference points. Install and press securely to full adhesive conClean away any reference points. EXTERIOR NAME PLATES ADHESIVE ATTACHED REMOVAL (1) Mark reference points before removing. (2) Using a heat gun gently apply heat in a circular motion to loosen the adhesive bond. (3) With your fingernail lift up and peel away badgeing/tape from panel, using a heat gun as you go. (4) Clean off all traces of adhesive from the panel(s) with a general purpose adhesive remover. INSTALLATION (1) Clean panel surface with isopropy alcohol. (2) Remove paper carrier and align badgeing/tape to reference points or adjacent panel. (3) Install and press securely, using a plastic spreader to eliminate all air bubbles. (4) Remove top protective carrier. (5) Clean away any reference points. REMOVAL INSTALLATION (1) Place fender in position on vehicle. (2) From inside engine compartment, start the center upper rail bolt. install all the bolts attaching fender to upper rail and tighten. (3) Install fender to lower cowl panel bolt. (4) Install fender to rocker panel bolt. (5) Place fascia into position. (6) Install outboard cowl grille/fender bracket screw. (7) Install fender to fascia nuts. (8) Install inner splash shield. (9) Install mud guard. (10) Install headlamp assembly. (Refer to 8 ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ HEADLAMP UNIT - INSTALLATION) (11) Check fender for flush and gap. Fig. 8 FENDER 1 - FASTENERS 2 - FENDER 3 - FASTENERS 23 - 52 EXTERIOR FUEL FILL DOOR REMOVAL (1) Remove left quarter trim panel. (2) Remove water shield patch covering access hole in C-pillar. (3) Disengage latch release link from clip on fuel fill blocker latch arm (Fig. 12). (4) Open fuel fill door. (5) Remove screws holding fuel fill neck to fuel filler housing. (6) Position fuel fill neck out of the way. (7) Reaching inside fuel filler housing, release clips holding housing to quarter panel (Fig. 9). (8) Remove fuel fill door from vehicle. (9) Disengage clip holding link to fuel fill door (Fig. 13). (10) Remove link from fuel fill door. RS (11) Engage latch release link into clip on fuel fill blocker latch arm. (12) Verify fuel fill blocker latch operation. (13) Install water shield patch to cover access hole in C-pillar. (14) Install left quarter trim panel. FUEL FILL DOOR BLOCKER LATCH REMOVAL (1) Remove left quarter trim panel. (2) Remove water shield patch covering access hole in C-pillar. (3) Disengage latch release link from clip on fuel fill blocker latch arm (Fig. 12). (4) Remove screws holding fuel fill blocker latch to C-pillar (Fig. 10). (5) Remove fuel fill blocker latch from vehicle. Fig. 9 FUEL FILLER HOUSING AND DOOR 1 2 3 4 5 - FUEL FILLER HOUSING W/LATCH CLIP FUEL FILLER HOUSING DOOR CLIPS FIX CLIP INSTALLATION (1) Install spring to housing and door (2) Snap door into housing. (3) Insert lockout link into clip on fuel fill door. (4) Engage clip to hold link to fuel fill door. (5) Insert lockout link through grommet in panel between inner and outer quarter panel. (6) Close fuel fill door. (7) Install fuel filler housing to outer quarter panel. (8) Verify that all clips on fuel filler housing are fully engaged to outer quarter panel. (9) Place fuel fill neck in position. (10) Install screws to hold fuel fill neck to fuel filler housing. Fig. 10 FUEL FILL 1 - FUEL FILLER BLOCKER LATCH ARM 2 - C-PILLAR INSTALLATION (1) Position fuel fill blocker latch on vehicle. (2) Install screws to hold fuel fill blocker latch to C-pillar. (3) Engage latch release link into clip on fuel fill blocker latch arm with fuel door in the closed position. (4) Install water shield patch to cover access hole in C-pillar. (5) Verify fuel fill blocker latch operation. (6) Install left quarter trim panel. EXTERIOR RS FUEL FILL DOOR BLOCKER LATCH STRIKER REMOVAL (1) Remove sliding door trim panel. (2) Remove sound shield as necessary to access striker (3) Remove screws attaching fuel fill door blocker latch striker to sliding door rear end frame (Fig. 11). (4) Remove fuel fill door blocker latch striker from vehicle. 23 - 53 (6) Reaching inside fuel filler housing, release clips holding housing to outer quarter panel. (7) Remove fuel filler housing and lockout link from vehicle. (8) Disengage clip holding link to fuel fill door (Fig. 13). (9) Remove link from fuel fill door. Fig. 12 FUEL FILLER LOCKOUT LINK AT LATCH ARM Fig. 11 FUEL FILL DOOR BLOCKER LATCH STRIKER 1 2 3 4 5 - FUEL FILLER LOCKOUT LINK C-PILLAR FUEL FILLER BLOCKER LATCH ARM PLASTIC LINK CLIP INNER QUARTER PANEL 1 - LEFT SLIDING DOOR 2 - FUEL FILLER STOP STRIKER INSTALLATION (1) Position fuel fill door blocker latch striker on vehicle. (2) Install screws attaching fuel fill door blocker latch striker to sliding door rear end frame. (3) Install sliding door sound shield. (4) Install sliding door trim panel. FUEL FILL DOOR BLOCKER LOCKOUT LINK REMOVAL (1) Remove left quarter trim panel. (2) Remove water shield patch covering access hole in C-pillar. (3) Disengage fuel filler lockout link from clip on fuel fill blocker latch arm (Fig. 12). (4) Open fuel fill door. (5) Remove screws holding fuel filler housing to fuel filler tube neck. Fig. 13 FUEL FILLER LOCKOUT LINK 1 - FUEL FILLER LOCKOUT LINK 2 - FUEL FILLER OPENING 3 - QUARTER PANEL 23 - 54 EXTERIOR RS FUEL FILL DOOR BLOCKER LOCKOUT LINK (Continued) INSTALLATION (1) Insert link into clip on fuel fill door. (2) Engage clip to hold link to fuel fill door. (3) Insert lockout link through grommet in panel between inner and outer quarter panel. (4) Close fuel fill door. (5) Install fuel filler housing to outer quarter panel. (6) Verify that all clips on fuel filler housing are fully engaged to outer quarter panel. (7) Engage fuel filler lockout link into clip on fuel fill blocker latch arm. (8) Install water shield patch covering access hole in C-pillar. (9) Install left quarter trim panel. GRILLE OPENING REINFORCEMENT REMOVAL (1) Release hood latch and open hood. (2) Remove bolts attaching hood latch to crossmember and position latch out of the way. (3) Remove radiator sight shield. (4) Remove engine air inlet resonator. (5) Remove hood cable. (6) Remove hood prop rod. (7) Remove screw attaching coolant recovery bottle to crossmember. (8) Remove bolts attaching radiator isolators to crossmember. (9) Remove bolts attaching ends of crossmember to radiator closure panel (Fig. 14). (10) Lift crossmember upward and away from radiator closure panel. (11) Remove crossmember from vehicle. INSTALLATION (1) Place radiator closure panel crossmember in position on vehicle. (2) Insert ends of crossmember between layered metal sections of radiator closure panel at each side of radiator. Fig. 14 RADIATOR CLOSURE PANEL CROSSMEMBER 1 - RADIATOR CLOSURE PANEL CROSSMEMBER 2 - FRONT FASCIA (3) Align with paint breaks around bolt heads. (4) Install bolts attaching ends of crossmember to radiator closure panel (Fig. 14) . Tighten bolts to 19 N·m (14 ft. lbs.) torque. (5) Install bolts attaching radiator isolators to crossmember. (6) Install screw attaching coolant recovery bottle to crossmember. (7) Install bolt attaching air cleaner housing to crossmember. (8) Install engine air inlet resonator. (9) Install radiator sight shield. (10) Install hood prop rod. (11) Align hood latch by placing latch over net pierce tabs. If alignment is required, flatten tabs. (12) Install bolts attaching hood latch to crossmember. Tighten bolts to 13.5 N·m (10 ft. lbs.) torque. (13) Verify hood latch operation and hood alignment. EXTERIOR RS FRONT WHEELHOUSE SPLASH SHIELD REMOVAL (1) Hoist and support vehicle on safety stands. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE). (2) Remove front wheel. (3) Remove push pin fasteners attaching splash shield to frame rail forward of suspension. (4) Remove push pin fasteners attaching splash shield to frame rail rearward of suspension. (5) Remove screws attaching wheelhouse splash shield to front fender and front bumper fascia. (6) Remove splash shield from vehicle (Fig. 15). 23 - 55 INSTALLATION (1) Place splash shield in position on vehicle (Fig. 15). (2) Install push pin fasteners attaching splash shield to frame rail forward of suspension. (3) Install push pin fasteners attaching splash shield to frame rail rearward of suspension. (4) Install screws attaching wheelhouse splash shield to front fender. (5) Install front wheel. (6) Lower vehicle. LUGGAGE RACK RISER REMOVAL (1) Remove two fasteners from the front riser. Gently pull up on the luggage rack side rail and detach the riser snap to remove riser from the rail (Fig. 16). (2) Repeat for the opposite side, if necessary. (3) Remove front riser(s) from vehicle (Fig. 17). Fig. 15 FRONT WHEELHOUSE SPLASH SHIELD 1 2 3 4 - FRONT FENDER WHEELHOUSE SPLASH SHIELD - PUSH PIN FASTENERS - ACCESSORY DRIVE SPLASH SHIELD - SCREWS Fig. 16 LUGGAGE RACK RISER COVER 1 2 3 4 - FRONT RISER COVER LOCK TABS LUGGAGE RACK SIDE RAIL FRONT RISER 23 - 56 EXTERIOR RS LUGGAGE RACK RISER (Continued) Fig. 17 LUGGAGE RACK, CROSSBARS AND RISER COVER 1 - LUGGAGE RACK SIDE RAILS 2 - SCREWS 3 - CROSSBARS 4 - FRONT RISER COVER 5 - RIV-NUTS INSTALLATION (1) Place front riser into position on luggage rack side rail. (2) Install two fasteners into the riser. (3) Repeat for the opposite side, if necessary. LUGGAGE RACK CROSSBAR REMOVAL (1) Remove luggage rack front risers. (2) Depress stanchion levers down until they click into the unlock position. (Fig. 18). Work from side to side sliding the crossbar assembly forward moving a little at a time to ensure it remains perpendicular to the side rails. (3) Remove crossbar from vehicle. Fig. 18 LUGGAGE RACK CROSSBAR 1 2 3 4 5 - LUGGAGE RACK CROSSBAR SLIDE LOCK FRONT RISER COVER FRONT RISER EXTERIOR RS 23 - 57 LUGGAGE RACK CROSSBAR (Continued) INSTALLATION NOTE: The crossbar assemblies are designed to be installed in only one way. Check top and bottom surfaces of the crossbar for the word FRONT and directional arrows. The directional arrows must point toward the front of the vehicle. (1) Place crossbar in position on vehicle. (2) Work from side to side sliding the crossbar assembly back a little at a time to ensure it remains perpendicular to the side rails. (3) Position first crossbar assembly crossbar at the second most rearward locator holes. Press the top of the stanchion lever to lock it into position. (4) Position the second crossbar assembly in the second hole from the front. Lock into place. (5) Place luggage rack riser into position. (6) Install two fasteners into riser. Tighten fasteners to 4 mm (35 in. lbs.) torque. REAR QUARTER PANEL/ FENDER AIR EXHAUSTER DESCRIPTION Air exhausters, designed to conform to the body structure, allow air entering at the front of the vehicle to flow out the back. By reducing air pressure within the vehicle, the exhausters also reduce blower noise at any given air flow level compared to operating without them and help reduce door closing effort. They are located in the lower rear comers of the body. Fig. 19 AIR EXHAUSTER - SWB 1 - LOWER APERTURE PANEL 2 - AIR EXHAUSTER remove the air exhauster from the short wheelbase model. Refer to SHORT WHEELBASE . (1) Remove the quarter trim panel from the inside of the left or right quarter inner panel (Refer to 23 BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - REMOVAL) or (Refer to 23 - BODY/INTERIOR/ LEFT QUARTER TRIM PANEL - REMOVAL). (2) Using a trim stick or another suitable wide flat bladed tool, carefully pry the air exhauster away from the opening in the lower aperture panel until the snap features release (Fig. 20). REMOVAL SHORT WHEELBASE (1) Remove the rear fascia from the body. (Refer to 13 - FRAMES & BUMPERS/BUMPERS/REAR FASCIA - REMOVAL). (2) Using a trim stick or another suitable wide flat bladed tool, carefully pry the air exhauster away from the opening in the lower aperture panel until the snap features release (Fig. 19). (3) Remove the air exhauster from the hole in the lower aperture panel. LONG WHEELBASE NOTE: Models with the optional rear heater and air conditioner do not have an air exhauster on the right side of the vehicle, but have a plastic plug installed in the right lower aperture panel. This plug is removed using the same procedure used to Fig. 20 AIR EXHAUSTER - LWB 1 - AIR EXHAUSTER 2 - PLUG 3 - LOWER APERTURE PANEL (1) Remove the air exhauster from the hole in the lower aperture panel. 23 - 58 EXTERIOR RS REAR QUARTER PANEL/FENDER AIR EXHAUSTER (Continued) INSTALLATION SHORT WHEELBASE (1) Position the air exhauster to the hole in the lower aperture panel (Fig. 19). (2) Using hand pressure, press the air exhauster into the opening in the lower aperture panel until the snap features are fully engaged. (3) Reinstall the rear fascia onto the body. (Refer to 13 - FRAMES & BUMPERS/BUMPERS/REAR FASCIA - INSTALLATION). LONG WHEELBASE NOTE: Models with the optional rear heater and air conditioner do not have an air exhauster on the right side of the vehicle, but have a plastic plug installed in the right lower aperture panel. This plug is installed using the same procedure used to install the air exhauster onto the short wheelbase model. Refer to SHORT WHEELBASE . (1) Position the air exhauster to the hole in the lower aperture panel (Fig. 20). (2) Using hand pressure, press the air exhauster into the opening in the lower aperture panel until the snap features are fully engaged. (3) Reinstall the quarter trim panel onto the inside of the left or right quarter inner panel. (Refer to 23 BODY/INTERIOR/RIGHT QUARTER TRIM PANEL - INSTALLATION) or (Refer to 23 - BODY/INTERIOR/LEFT QUARTER TRIM PANEL - INSTALLATION). ROOF JOINT MOLDING REMOVAL The RAP molding is set with body side molding tape. The temperature in the work area and the vehicle should be at least 21° C (70° F) to avoid damaging the RAP moldings. (1) Warm the affected stick-on molding and body metal to approximately 38° C (100° F) using a suitable heat lamp or heat gun. (2) Pull stick-on molding from painted surface. (3) Remove adhesive tape residue from painted surface of vehicle. Use a 3M Scotch-Brite™ Molding Adhesive and Stripe Removal Discs, or equivalent, to clean adhesive residue from painted surfaces. The adhesive removal discs are available from automotive paint suppliers. Refer to instructions supplied with the discs for proper usage. INSTALLATION The RAP molding is set with body side molding tape. The temperature in the work area and the vehicle should be at least 21° C (70° F) to avoid damaging the RAP moldings. (1) If molding is to be reused; (a) Remove tape residue from molding. (b) Clean back of molding with Mopart Super Kleen solvent, or equivalent. (c) Wipe molding dry with lint free cloth. (d) Apply new body side molding (two sided adhesive) tape to back of molding. (2) Clean body surface with Mopart Super Kleen solvent, or equivalent. Wipe surface dry with lint free cloth. (3) Remove protective cover from tape on back of molding. (4) Apply molding to body from front of vehicle to rear. (5) Using a roller tool, roll molding onto body panel with enough force to assure adhesion and not bend roof panels. SIDE VIEW MIRROR REMOVAL (1) Using a trim stick or equivalent, remove the trim cover (Fig. 21). (2) Remove the bolts. (3) Remove the mirror from the pillar. (4) Disconnect the electrical connector, if equipped. INSTALLATION (1) (2) (Fig. (3) (4) Connect the electrical connector, if equipped. Place side view mirror in position on vehicle 21). Install the bolts. Install the trim cover. EXTERIOR RS 23 - 59 SIDE VIEW MIRROR (Continued) (2) Disconnect the heated mirror electrical connectors from the terminals on the mirror glass holder, if equipped. INSTALLATION CAUTION: It is important to make sure the motor is square to the glass holder (attaching fingers) prior to glass holder attachment, otherwise the glass holder could be installed incorrectly causing poor retention and possible repeat failure. (1) Position the new mirror glass holder to the mirror assembly. NOTE: Position the mirror glass holder so that the moisture drain hole on the mirror glass holder assembly is facing downward. (2) Align the mirror glass holder’s attaching fingers to the mirror motor housing. Fig. 21 SIDE VIEW MIRROR 1 2 3 4 - MIRROR - MIRROR TRIM COVER - A-PILLAR - BOLTS SIDE VIEW MIRROR GLASS REMOVAL WARNING: ALWAYS WEAR EYE AND HAND PROTECTION WHEN SERVICING THE MIRROR ASSEMBLY. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY FROM BROKEN GLASS. (1) Carefully pull/pry the broken glass holder from the mirror assembly. NOTE: Ensure that the protective rubber cover of the mirror motor housing is positioned correctly around the bottom of the fingers area. (3) Using one hand, firmly press the mirror glass holder assembly into place while at the same time supporting the housing assembly from the backside with the other hand. NOTE: Pressure must be applied equally over the center portion of the mirror to engage the mirror glass holder’s attaching fingers to the corresponding fingers on the housing assembly. One or more clicks may be heard when finger engagement takes place. (4) Verify retention of the mirror glass holder assembly by gently pulling outward on the mirror glass holder. 23 - 60 HOOD RS HOOD TABLE OF CONTENTS page HINGE REMOVAL . . . INSTALLATION HOOD REMOVAL . . . INSTALLATION LATCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 . . . . . . . . . . . . . . . . . . . . . . . . . 60 . . . . . . . . . . . . . . . . . . . . . . . . . . 60 . . . . . . . . . . . . . . . . . . . . . . . . . 61 page INSTALLATION . . . . . . LATCH RELEASE CABLE REMOVAL . . . . . . . . . . INSTALLATION . . . . . . LATCH STRIKER REMOVAL . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61 . . . . . . . . . . . . . . . . . . . 61 . . . . . . . . . . . . . . . . . . . 62 . . . . . . . . . . . . . . . . . . . 62 . . . . . . . . . . . . . . . . . . . 62 . . . . . . . . . . . . . . . . . . . . . . . . . . 61 INSTALLATION HINGE REMOVAL (1) Remove Front Wiper Unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL) for procedure. (2) Raise hood. (3) Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to provide reference marks for installation. (4) Remove pivot bolt from the body half of hood hinge and use suitable device to support the hood. (5) Remove bolts attaching body half of hood hinge to front fender flange and remove hinge from vehicle (Fig. 1). (1) If necessary, paint new hinge before installation. (2) Place body half of hood hinge in position on vehicle. (3) Install bolts attaching hood hinge to front fender flange. Tighten bolts to 8 N·m (70 in. lbs.) torque. (4) Install pivot bolt to the body half of hood hinge. Tighten bolts to 28 N·m (21 ft. lbs.) torque. (5) Install Front Wiper Unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION) for proper procedures. (6) Align all marks and secure bolts. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. Shims can be added or removed under hood hinge to achieve proper hood height. Tighten bolts to 13.5 N·m (10 ft. lbs.) torque.Close hood. HOOD REMOVAL Fig. 1 HOOD HINGE 1 2 3 4 5 - HOOD HOOD HALF OF HOOD HINGE HOOD HINGE PIVOT BUSHING BODY HALF OF HOOD HINGE FENDER (1) Raise hood to full up position. (2) Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to provide reference marks for installation. (3) Remove the top bolts attaching hood to hinge and loosen the bottom bolts until they can be removed by hand (Fig. 2). (4) With assistance from a helper at the opposite side of the vehicle to support the hood, remove bottom bolts attaching hood to hinge. (5) Remove the hood from the vehicle. HOOD RS 23 - 61 HOOD (Continued) Fig. 3 HOOD LATCH Fig. 2 HOOD 1 - HOOD 2 - HOOD LATCH STRIKER 3 - HOOD HALF OF HOOD HINGE 1 - HOOD RELEASE CABLE 2 - HOOD LATCH 3 - RADIATOR CLOSURE PANEL CROSSMEMBER INSTALLATION (1) Place hood in position on vehicle. With assistance from a helper at the opposite side of the vehicle to support the hood, install bottom bolts attaching hood to hinge finger tight. (2) Install top bolts attaching hood to hinge finger tight. (3) Position bolts at marks and tighten. Tighten bolts to 13.5 N·m (120 in. lbs.) torque. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. (4) Verify hood operation and alignment. LATCH REMOVAL (1) Release hood latch and open hood. (2) Remove bolts attaching hood latch to radiator closure panel crossmember (Fig. 3). (3) Remove hood latch from crossmember. (4) Disconnect hood release cable from hood latch (Fig. 4). (5) Remove hood latch from vehicle. INSTALLATION (1) Position hood latch on vehicle. (2) Connect hood release cable from hood latch. (3) Position hood latch on crossmember. (4) Align hood latch by placing latch over net pierced tabs. If alignment is required, flatten or grind tabs. Fig. 4 HOOD 1 - RELEASE CABLE CASE 2 - HOOD LATCH 3 - RELEASE CABLE END (5) Verify hood operation and alignment. Adjust as necessary. (6) Tighten attaching bolts to 13.5 N·m (10 ft. lbs.) torque. LATCH RELEASE CABLE REMOVAL (1) Remove hood latch. (2) Disengage cable end from hood latch locking mechanism. (3) Slide cable case end sideways in keyhole slot of hood latch while pinching barb on cable case closed. (4) Remove cable from latch (Fig. 4). (5) Remove hood release handle from instrument panel. 23 - 62 HOOD RS LATCH RELEASE CABLE (Continued) (6) Disengage rubber grommet cable insulator from hole in dash panel. (7) Attach a suitable length of mechanic’s wire to latch end of cable to assist cable installation. (8) Route cable back from latch through engine compartment toward dash panel near power brake booster (Fig. 5). (9) Remove attaching clips from cable case. (10) From inside vehicle, pull cable through dash panel until mechanic’s wire is exposed. (11) Disconnect cable from mechanic’s wire. (12) Remove hood release cable from vehicle. (3) Route cable forward through engine compartment toward latch by pulling on mechanic’s wire (Fig. 5) . (4) Disconnect mechanic’s wire from cable. (5) Engage rubber grommet cable insulator into hole in dash panel. (6) Install hood release handle into instrument panel. (7) Place cable in position on latch. (8) Slide cable case end sideways into keyhole slot of hood latch. (9) Engage cable end into hood latch locking mechanism. (10) Install hood latch. (11) Install attaching clips to cable case and install clips into original holes in strut tower, fender, headlamp area, and radiator closure panel crossmember. LATCH STRIKER REMOVAL (1) Release hood latch and open hood. (2) Remove bolts attaching striker to inside of hood. (3) Remove hood latch striker from vehicle. INSTALLATION Fig. 5 HOOD RELEASE CABLE ROUTING 1 - GROMMET 2 - HOOD RELEASE CABLE 3 - RADIATOR CLOSURE PANEL CROSSMEMBER INSTALLATION (1) Place hood release cable in position under instrument panel. (2) Attach latch end of hood release cable to mechanic’s wire protruding through dash panel. (1) Position hood latch striker on vehicle. (2) Install bolts attaching hood latch striker to hood. (3) Align hood latch striker to engage smoothly into hood latch. (4) Verify hood operation and alignment. Adjust as necessary. (5) Tighten attaching bolts to 13.5 N·m (10 ft. lbs.) torque. INSTRUMENT PANEL RS 23 - 63 INSTRUMENT PANEL TABLE OF CONTENTS page CLUSTER BEZEL REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . CUP HOLDER REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . GLOVE BOX REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . GLOVE BOX LATCH REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . GLOVE BOX LATCH STRIKER REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . INSTRUMENT PANEL ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . INSTRUMENT PANEL CENTER BEZEL REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63 . . . . . . . . . 63 . . . . . . . . . 64 . . . . . . . . . 64 . . . . . . . . . 64 . . . . . . . . . 64 . . . . . . . . . 64 . . . . . . . . . 64 . . . . . . . . . 64 . . . . . . . . . 65 . . . . . . . . . 65 . . . . . . . . . 67 . . . . . . . . . 68 . . . . . . . . . 68 page INSTRUMENT PANEL END CAP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT PANEL TOP COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . LOWER CONSOLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . LOWER INSTRUMENT PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . LOWER STEERING COLUMN COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . STEERING COLUMN COVER BACKING PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . OVER STEERING COLUMN COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . CLUSTER BEZEL REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove Over Steering Column Bezel by lifting it straight up with a firm pull. (3) Remove the four bezel attaching screws (Fig. 1). (4) Tilt the steering column in the full down position. (5) Pull rearward on the cluster bezel and remove. INSTALLATION (1) Maneuver cluster bezel over steering column and into position (Fig. 1). (2) Install the four bezel attaching screws. (3) Install the Over Steering Column Bezel by positioning it over the retaining slots and firmly snapping it into place. (4) Connect the battery negative cable. Fig. 1 CLUSTER BEZEL 1 - INSTRUMENT PANEL 2 - CLUSTER BEZEL . . 68 . . 68 . . 69 . . 69 . . 69 . . 69 . . 70 . . 70 . . 70 . . 70 . . 70 . . 71 . . 71 . . 71 23 - 64 INSTRUMENT PANEL RS CUP HOLDER GLOVE BOX REMOVAL REMOVAL (1) Remove the screw access cover from the bottom of the center bezel. (2) Remove the center bezel attaching screws. (3) Using a trim stick (special tool #C-4755) or equivalent, gently pry out on the edge of the instrument panel center bezel. Hang off to the side leaving the accessory switches connected. (4) Pull the cup holder assembly rearward to disengage the rear guide studs from instrument panel (Fig. 2). (1) Open glove box. (2) Push in on sides of glove box bin and lower door. (3) Pivot glove box downward and disengage hinge hooks from instrument panel. (4) Remove glove box. INSTALLATION (1) Place glove box in position. (2) Engage hinge hooks into instrument panel and pivot glove box upward. (3) Push in sides of glove box bin and snap glove box assembly into instrument panel. (4) Close glove box door. GLOVE BOX LATCH REMOVAL (1) Open glove box. (2) Push in on sides of glove box bin and lower door. (3) Pivot glove box downward and disengage hinge hooks from instrument panel. (4) Remove glove box. (5) Remove the assembly screws. (6) Disassemble the glove box. (7) Separate the latch from the glove box assembly. Fig. 2 CUP HOLDER 1 - LOWER INSTRUMENT PANEL 2 - CUPHOLDER AND TRACK INSTALLATION (1) Ensure the cup holder assembly is in the closed position. The cup holder assembly must be installed as an assembly to ensure proper track position. (2) Place the cup holder assembly into position in the lower instrument panel and slide into opening until the rear guide struts snap into place (Fig. 2). (3) Install the center bezel. (4) Install the center bezel attaching screws (5) Install the cup holder. Align the cup holder assembly with the track and firmly slide shut to engage retaining tang. (6) Install the screw access cover to the bottom of the center bezel. INSTALLATION (1) Install the latch onto the glove box assembly. (2) Assemble the glove box. (3) Install the assembly screws. (4) Engage hinge hooks into instrument panel and pivot glove box upward. (5) Push in sides of glove box bin and snap glove box assembly into instrument panel. (6) Close glove box door. GLOVE BOX LATCH STRIKER REMOVAL (1) (2) ment (3) Open glove box door. Remove screws holding lock striker to instrupanel. Remove glove box latch striker. RS INSTRUMENT PANEL 23 - 65 GLOVE BOX LATCH STRIKER (Continued) INSTALLATION (1) Install the glove box latch striker. (2) Install the screws holding latch striker to instrument panel. (3) Close glove box door. INSTRUMENT PANEL ASSEMBLY REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the lower console: (a) Remove six retaining screws. (b) Pull rearward and disconnect the auxiliary power outlet. (c) Remove lower console from vehicle. (3) Remove the bolts attaching the lower supports to the instrument panel frame (Fig. 3). (4) Remove the bolts attaching the lower supports to the floor pan. (5) Disconnect the wire connectors from the Passenger Airbag. (6) Remove the two screws to each right and left cowl trim covers. (7) Remove the both left and right side A-pillar trim covers using a trim stick (special tool #C-4755) or equivalent gently pry out on the trim covers and remove. (8) Remove the glove box: (a) Push in on sides of glove box bin and lower door. (b) Pivot glove box downward and disengage hinge hooks from instrument panel. (c) Remove glove box from vehicle. (9) Disconnect the antenna lead connector from behind the glove box. (10) Remove the four screws to the lower steering column cover. (11) Remove the eight screws to the steering column backing plate. (12) Unclip the Data Link Connector (DLC) from the steering column backing plate. (13) Remove two screws to the left side instrument panel silencer and remove (Fig. 4). (14) Disconnect the left side wiring: (a) Brake switch. (b) Main bulkhead connector. (c) Five harness connectors. (d) Driver airbag connector. (15) Remove the two screws to the hood release handle. (16) Remove five screws to steering column backing plate and remove (Refer to 23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER - REMOVAL). (17) Remove the two steering column shroud retaining screws. Separate the shrouds and remove from vehicle. (18) Remove the screws attaching the instrument panel reinforcement and remove (Fig. 5). (19) Disconnect the steering column wiring. There are seven connectors and then unclip the harness from the column. (20) Disconnect the Occupant Restraint Controller (ORC) harness connector. (21) Remove the four nuts retaining the steering column to the dash panel steering column mounting bracket and lower column to the floor (Fig. 6). (22) Remove the four nuts attaching the instrument panel to the brake pedal support bracket. (23) Loosen the left side roll down bolt (Fig. 7). (24) Remove the left side A-pillar retaining bolts. There are two 13 mm bolts and one 10 mm bolt. (25) If equipped with a mechanical transmission range indicator: (a) Remove the indicator cable loop. (b) Remove the clip holding gear shift cable end to the gear selector adapter. (c) Pull the cable end from gear selector. (d) Disconnect the clip for the indicator cable and guide tube from the shift cable bracket and move out of the way. (26) Remove the instrument panel top cover. Using a trim stick or equivalent, gently pry up on the front edge of the top cover, pull rearward and remove from vehicle. (27) Disconnect the right side wire connectors from the HVAC behind the glove box area and the two antenna connectors behind the glove box hinge. (28) Remove the right end cover by pulling outboard. (29) Remove the right side A-pillar retaining bolts. There are two 13 mm bolts and one 10 mm bolt. (30) Loosen the right side roll down bolt. (31) Disconnect the two front window defroster grid wire connectors. One on each side of vehicle. (32) Remove both the left and right power mirrors: (a) Using a trim stick or equivalent, gently pry out on mirror trim cover. (b) Open door and remove the three torx retaining screws. (c) Disconnect the wire connector and remove mirror from the vehicle. (33) Feed power mirror wire harness inboard through the A-pillar. (34) Remove the bolts attaching the instrument panel frame to the dash panel below windshield opening. (35) With the help of an assistant remove the instrument panel from vehicle. Lift the instrument 23 - 66 INSTRUMENT PANEL RS INSTRUMENT PANEL ASSEMBLY (Continued) panel up off the HVAC so you won’t damage the sealing surface of the distribution duct. If the instrument panel is being replaced, transfer all parts to the new instrument panel assembly. Fig. 5 INSTRUMENT PANEL LOWER REINFORCEMENT Fig. 3 INSTRUMENT PANEL CENTER STACK RIGHT & LEFT REINFORCEMENTS 1 - LOWER RIGHT REINFORCEMENT 2 - STEERING WHEEL ASSEMBLY 3 - INSTRUMENT PANEL LOWER REINFORCEMENT 1 - INSTRUMENT PANEL 2 - CENTER STACK RIGHT & LEFT REINFORCEMENT Fig. 6 STEERING COLUMN MOUNTING BRACKET 1 2 3 4 Fig. 4 INSTRUMENT PANEL LEFT SILENCER 1 - INSTRUMENT PANEL 2 - INSTRUMENT PANEL LEFT SILENCER - INSTRUMENT PANEL INSTRUMENT PANEL STEERING BRACKET DASH PANEL REINFORCEMENT DASH PANEL STEERING COLUMN MOUNTING BRACKET INSTRUMENT PANEL RS 23 - 67 INSTRUMENT PANEL ASSEMBLY (Continued) Fig. 7 INSTRUMENT PANEL REMOVAL 1 - INSTRUMENT PANEL 2 - FIVE ATTACHING SCREWS 3 - 13 mm BOLT - TWO ON EACH SIDE INSTALLATION (1) With the help of an assistant place the instrument panel into vehicle on roll down bolts. As you roll the instrument panel up, lift the instrument panel up so the duct work does not bind or bend and you can set it down on the HVAC housing to get the proper seal at the distribution duct. Get one bolt started in the dash panel. (2) Install the left and right side A-pillar retaining bolts. There are two 13 mm bolts and one 10 mm bolt. The 10 mm bolts need to be installed first to insure proper positioning of the Instrument panel in the vehicle. Start the right side 10 mm bolt first (Fig. 7). (3) Feed power mirror wire harness outboard through the A-pillar. (4) Install both the left and right power mirrors: (a) Connect the wire connector and install the mirror onto the vehicle. (b) Install the three torx retaining screws. (c) Using a firm push, snap the mirror trim cover into place. (5) Connect the two front window defroster grid wire connectors. One on each side of vehicle. (6) Tighten the right side roll down bolt. (7) Install the right end cover. Position over retaining slots and firmly snap into place. 4 - ROLL DOWN BRACKET 5 - 10 mm BOLT - STARTING BOLT ONE EACH SIDE (8) Connect the right side wire connectors to the HVAC behind the glove box area and the two antenna connectors behind the glove box hinge. (9) Install the bolts attaching the instrument panel frame to the dash panel below windshield opening. (10) Install the instrument panel top cover. Slide the front edge of the top cover toward dash panel, and firmly snap down the rear edge of the to cover to engage clips. (11) If equipped with a mechanical transmission range indicator: (a) Connect the clip for the indicator cable and guide tube to the shift cable bracket. (b) Install the cable end to the gear selector. (c) Install the clip holding the gear shift cable end to the gear selector adapter. (d) Install the indicator cable loop. (12) Tighten the left side roll down bolt. (13) Install the four nuts attaching the instrument panel to the brake pedal support bracket. (14) Install the four nuts retaining the steering column and lower to the floor (Fig. 6). (15) Connect the Occupant Restraint Controller (ORC) harness connector. (16) Connect the steering column wiring. There are seven connectors and then clip the harness to the column. 23 - 68 INSTRUMENT PANEL RS INSTRUMENT PANEL ASSEMBLY (Continued) (17) Install the screws attaching the instrument panel reinforcement (Fig. 5). (18) Connect the shrouds and install the two steering column shroud retaining screws. (19) Install five screws to the left under column instrument panel reinforcement brace. (20) Install the two screws to the hood release handle. (21) Connect the left side wiring: (a) Brake switch. (b) Main bulkhead connector. (c) Five harness connectors. (d) Driver airbag connector. (22) Install two screws to the left side instrument panel silencer (Fig. 4). (23) Clip the Data Link Connector (DLC) to the steering column backing plate. (24) Install the eight screws to the steering column backing plate. (25) Install the four screws to the lower steering column cover. (26) Install the glove box: (a) Install glove box into the vehicle. Line up the hinges and firmly snap together. (b) Push in on sides of glove box bin and raise door. (27) Install the both left and right side A-pillar trim covers. Position trim cover over slots and firmly snap into place. (28) Install the two screws to each right and left cowl trim covers. (29) Connect the wire connectors to the Passenger Airbag. (30) Install the bolts attaching the lower supports to the floor pan. (31) Install the bolts attaching the lower supports to the instrument panel frame (Fig. 3). (32) Install the lower console: (a) Install lower console to vehicle. (b) Connect the auxiliary power outlet. (c) Install the six retaining screws. (33) Connect the battery negative cable. (5) Using a trim stick or equivalent, gently pry out on the edge of the instrument panel center bezel and pull outward. (6) Disconnect the wire connectors to the accessory switches and HVAC control. (7) Remove the instrument panel center bezel from the vehicle. Fig. 8 INSTRUMENT PANEL CENTER BEZEL 1 - LOWER INSTRUMENT PANEL 2 - INSTRUMENT PANEL CENTER BEZEL 3 - CUPHOLDER INSTALLATION (1) Place center bezel near opening and connect the wire connectors to the accessory switches and HVAC control. (2) Position the center bezel over the retaining slots and firmly snap the instrument panel center bezel into place (Fig. 8). (3) Install the two center bezel attaching screws. (4) Install the screw access cover to the bottom of the center bezel. INSTRUMENT PANEL CENTER BEZEL INSTRUMENT PANEL END CAP REMOVAL (1) Open passenger side front door. (2) Using a trim stick, disengage clips holding end cover to instrument panel (Fig. 9). (1) Disconnect and isolate the battery negative cable. (2) Insert the trim stick (special tool #C-4755) or equivalent between access cover and center bezel gently pry outward. (3) Carefully pry the access cover from the instrument panel (Fig. 8). (4) Remove the two center bezel attaching screws. REMOVAL INSTALLATION (1) Position end cover over retaining slots and firmly snap into place (Fig. 9). (2) Close passenger side front door. INSTRUMENT PANEL RS 23 - 69 INSTRUMENT PANEL END CAP (Continued) Fig. 9 INSTRUMENT PANEL END CAP 1 - INSTRUMENT PANEL 2 - INSTRUMENT PANEL END CAP INSTRUMENT PANEL TOP COVER Fig. 10 INSTRUMENT PANEL TOP COVER 1 - INSTRUMENT PANEL TOP COVER 2 - INSTRUMENT PANEL (3) Disconnect the auxiliary power outlet wire connector (if equipped). (4) Remove lower console from vehicle. REMOVAL (1) Remove A-pillar trim. Using a trim stick (special tool #C-4755) or equivalent, gently pry out and remove. (2) Using a trim stick, disengage clips attaching rear edge of top cover to instrument panel (Fig. 10). NOTE: The Instrument Panel Top Cover may be hard to unsnap from the instrument panel. Be sure not to mar, scuff, or damage the instrument panel pad. (3) Pull top cover rearward to disengage hooks attaching front of top cover to instrument panel. (4) Remove top cover from vehicle. INSTALLATION (1) Place instrument panel top cover in position on vehicle (Fig. 10). (2) Push top cover forward to engage hooks attaching front of top cover to instrument panel. (3) Engage clips attaching rear edge of top cover to instrument panel. (4) Pull top cover rearward. (5) Install A-pillar trim. LOWER CONSOLE REMOVAL (1) Remove screws attaching the lower console to floor bracket and instrument panel (Fig. 11). (2) Slide lower console rearward from around instrument panel supports. Fig. 11 INSTRUMENT PANEL FLOOR CONSOLE 1 - INSTRUMENT PANEL 2 - INSTRUMENT PANEL FLOOR CONSOLE INSTALLATION (1) Connect the auxiliary power outlet wire connector (if equipped). (2) Install the lower console into the vehicle (Fig. 11). (3) Slide console forward around instrument panel supports. (4) Install the screws attaching lower console to floor bracket and instrument panel. 23 - 70 INSTRUMENT PANEL LOWER INSTRUMENT PANEL REMOVAL When servicing the lower instrument panel, refer to Body, Instrument Panel, and then the appropriate removal procedure. (1) Remove the right end cover. (2) Remove the lower steering column cover. (3) Remove the center bezel. (4) Remove the lower console. (5) Remove the cup holder and track. (6) Remove the glove box. (7) Remove the glove box latch striker. (8) Remove the glove box lamp. (9) Remove the eighteen screws holding the lower instrument panel to the reinforcement frame (Fig. 12). (10) Remove the lower instrument panel from vehicle. RS (8) Install the center bezel. (9) Install the lower steering column cover. (10) Install the right end cover. LOWER STEERING COLUMN COVER REMOVAL (1) Remove the four screws attaching the lower steering column cover to instrument panel (Fig. 13). (2) Remove the lower steering column cover from the vehicle. Fig. 13 LOWER STEERING COLUMN COVER 1 - STEERING COLUMN COVER BACKING PLATE 2 - STEERING COLUMN COVER INSTALLATION Fig. 12 LOWER INSTRUMENT PANEL 1 - INSTRUMENT PANEL 2 - LOWER INSTRUMENT PANEL INSTALLATION When servicing the lower instrument panel, refer to Body, Instrument Panel, and then the appropriate removal procedure. (1) Install the lower instrument panel into the vehicle (Fig. 12). (2) Install the eighteen screws holding the lower instrument panel to the reinforcement frame. (3) Install the glove box lamp. (4) Install the glove box latch striker. (5) Install the glove box. (6) Install the cup holder and track. (7) Install the lower console. (1) Install the lower steering column cover into the vehicle (Fig. 13). (2) Install the four screws attaching the lower steering column cover to instrument panel. STEERING COLUMN COVER BACKING PLATE REMOVAL (1) Remove lower steering column cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - REMOVAL). (2) Remove the park brake release handle link from the park brake release handle. (3) Remove screws attaching lower steering column backing plate to instrument panel (Fig. 13). (4) Unclip the Data Link Connector (DLC) from the lower steering column backing plate. INSTRUMENT PANEL RS 23 - 71 STEERING COLUMN COVER BACKING PLATE (Continued) (5) Remove lower steering column backing plate from vehicle. (2) Remove the over steering column cover from the vehicle. INSTALLATION (1) Install the steering column cover backing plate into vehicle (Fig. 13). (2) Clip the Data Link Connector (DLC) to the steering column cover backing plate (3) Install the screws attaching steering column cover backing plate to instrument panel. (4) Connect the park brake release handle link to the park release handle. (5) Install the lower steering column cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION). OVER STEERING COLUMN COVER REMOVAL (1) Taking a firm grasp of the over steering column cover front edge, give a quick upward pulling motion to disengage the cover from the instrument panel (Fig. 14). Fig. 14 OVER STEERING COLUMN COVER 1 - INSTRUMENT PANEL OVER STEERING COLUMN COVER 2 - INSTRUMENT PANEL INSTALLATION (1) Place the over steering column cover into position over the retaining slots and firmly snap into place (Fig. 14). 23 - 72 INTERIOR RS INTERIOR TABLE OF CONTENTS page A-PILLAR LOWER EXTENSION TRIM REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . A-PILLAR TRIM REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . ASSIST HANDLE REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . B-PILLAR LOWER TRIM REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . B-PILLAR UPPER TRIM REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . CARPETS AND FLOOR MATS REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . COWL TRIM REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . C-PILLAR TRIM REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . DOOR SILL TRIM PLATE REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . HEADLINER REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . LEFT D-PILLAR TRIM PANEL REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . LIFTGATE SILL PLATE REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . QUARTER TRIM BOLSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 . . . . . . . . . . 73 . . . . . . . . . . 73 . . . . . . . . . . 73 . . . . . . . . . . 73 . . . . . . . . . . 73 . . . . . . . . . . 73 . . . . . . . . . . 74 . . . . . . . . . . 74 . . . . . . . . . . 74 . . . . . . . . . . 74 . . . . . . . . . . 75 . . . . . . . . . . 75 . . . . . . . . . . 75 . . . . . . . . . . 75 . . . . . . . . . . 76 . . . . . . . . . . 76 . . . . . . . . . . 76 . . . . . . . . . . 76 . . . . . . . . . . 76 . . . . . . . . . . 77 . . . . . . . . . . 77 . . . . . . . . . . 77 . . . . . . . . . . 77 . . . . . . . . . . 77 page INSTALLATION . . . . . . . . . . . . . . . RIGHT QUARTER TRIM PANEL REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . LEFT QUARTER TRIM PANEL REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . REAR HEADER TRIM REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . REAR HVAC LOUVER REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . REAR VIEW MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . RIGHT D-PILLAR TRIM PANEL REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . SLIDING DOOR SILL PLATE REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . SUN VISOR REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . SUN VISOR SUPPORT REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . FLOOR CONSOLE TRAY REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . FLOOR CONSOLE TRAY - BRACKET ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77 . . . . . . . . . . 78 . . . . . . . . . . 78 . . . . . . . . . . 78 . . . . . . . . . . 78 . . . . . . . . . . 79 . . . . . . . . . . 79 . . . . . . . . . . 79 . . . . . . . . . . 79 . . . . . . . . . . 80 . . . . . . . . . . 80 . . . . . . . . . . 80 . . . . . . . . . . 80 . . . . . . . . . . 80 . . . . . . . . . . 80 . . . . . . . . . . 81 . . . . . . . . . . 81 . . . . . . . . . . 81 . . . . . . . . . . 81 . . . . . . . . . . 82 . . . . . . . . . . 82 . . . . . . . . . . 82 . . . . . . . . . . 82 INTERIOR RS 23 - 73 A-PILLAR LOWER EXTENSION TRIM REMOVAL (1) Remove instrument panel side cover. (2) Remove A-pillar extension trim from vehicle by disengaging hidden clips (Fig. 1). Fig. 2 A-PILLAR TRIM 1 - A-PILLAR 2 - CLIPS Fig. 1 A-PILLAR LOWER EXTENSION TRIM 1 - FRONT LOWER EXTENSION TRIM 2 - FRONT EXTENSION TRIM TO INSTRUMENT PANEL RETAINER 3 - CLIP 4 - COWL TRIM PANEL (5) Install the assist handle, if equipped. (Refer to 23 - BODY/INTERIOR/ASSIST HANDLE - INSTALLATION) ASSIST HANDLE REMOVAL INSTALLATION (1) Place A-pillar extension trim in position on vehicle (Fig. 1). (2) Install instrument panel side cover. A-PILLAR TRIM REMOVAL (1) Remove the assist handle if equipped. (Refer to 23 BODY/INTERIOR/ASSIST HANDLE REMOVAL) (2) Disengage hidden clips holding A-pillar trim panel to A-pillar (Fig. 2). (3) Remove A-pillar trim from vehicle. INSTALLATION (1) ment (2) (3) (4) Position foot on A-pillar trim panel into instrupanel top cover channel. Position A-pillar trim in vehicle. Align locator pins. Engage hidden clips. (1) Using a trim stick (C-4755), remove screw access covers from grab-handle. (2) Remove screws holding grab-handle to roof rail. (3) Remove grab-handle from vehicle. INSTALLATION (1) Place grab-handle in position on vehicle. (2) Install screws to hold grab-handle to roof rail. (3) Install screw access covers into grab-handle. B-PILLAR LOWER TRIM REMOVAL (1) Slide lower seat belt cover rearward to expose anchor bolt. (2) Remove bolt attaching lower seat belt anchor to floor. (3) Remove upper B-pillar trim cover. (4) Remove access panel from B-pillar trim (Fig. 3). 23 - 74 INTERIOR RS B-PILLAR LOWER TRIM (Continued) (5) Disengage hidden clips attaching lower trim cover to B-pillar. (6) Remove lower B-pillar trim cover from vehicle. (2) Lower shoulder belt height adjuster to the bottom of travel. (3) Remove shoulder belt turning loop from height adjuster. (4) Use a Snap-ont Trim Pad Remover tool (A179A), or equivalent, and remove shoulder belt height adjuster knob. (5) Remove shoulder belt bezel from trim cover (Fig. 3). (6) Remove screw attaching trim cover to B-pillar from inside bezel cavity. (7) Disengage hidden clips attaching trim cover to B-pillar. (8) Remove B-pillar trim cover from vehicle. INSTALLATION Fig. 3 LOWER B-PILLAR TRIM COVER 1 2 3 4 5 - B-PILLAR UPPER TRIM B-PILLAR UPPER PLUG POWER SLIDING DOOR SWITCH AND BEZEL BELT ASSEMBLY B-PILLAR LOWER TRIM INSTALLATION (1) Place lower B-pillar trim cover in position on vehicle (Fig. 3). (2) Insert seat belt through hole in lower B-pillar trim. (3) Engage hidden clips attaching lower trim cover to B-pillar. (4) Install access cover. (5) Install upper B-pillar trim cover. (6) Place seat belt anchor in position on floor so webbing is pointed rearward and slightly outboard. (7) Install bolt attaching lower seat belt anchor to floor. Tighten all seat belt bolts to 39 N·m (29 ft. lbs.) torque. (8) Verify that seat belt anchor does not interfere with seat track travel. B-PILLAR UPPER TRIM REMOVAL (1) Remove bolt attaching lower seat belt anchor to floor. (1) Insert seat belt through B-pillar trim and web guide (Fig. 3). (2) Place B-pillar trim cover in position on vehicle. (3) Engage hidden clips attaching trim cover to B-pillar. (4) Install shoulder belt bezel into trim cover. (5) Install height adjuster knob. (6) Install shoulder belt turning loop onto height adjuster. Tighten bolt to 39 N·m (29 ft. lbs.) torque. (7) Place seat anchor in position on floor so webbing is pointed rearward and slightly outboard. (8) Install bolt attaching lower seat belt anchor to floor. Tighten seat belt bolt to 39 N·m (29 ft. lbs.) torque. CARPETS AND FLOOR MATS REMOVAL (1) Remove front seats. (Refer to 23 - BODY/ SEATS/SEAT - REMOVAL) (2) Remove front center console. (3) Remove the remaining seats. Refer to the Owner’s Manual for the proper procedures. (4) Remove front cowl panels and sill plates. (5) Remove sliding door sill plates. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE REMOVAL) (6) Remove the cargo organizer, if equipped. (7) Remove liftgate scuff plate. (Refer to 23 BODY/INTERIOR/LIFTGATE SCUFF PLATE REMOVAL) (8) Remove lower B-pillar trim covers. (9) Remove D-pillar trim covers. (10) Remove Quarter trim panels. (11) Remove floor escutcheons (Fig. 4). (12) Remove the floor console trays. (Refer to 23 BODY/INTERIOR/FLOOR CONSOLE TRAY REMOVAL) INTERIOR RS 23 - 75 CARPETS AND FLOOR MATS (Continued) (13) Remove push pin fasteners attaching carpet to floor in front seat and rear area. (14) Roll carpet from under instrument panel to center of sliding door. (15) Roll and fold carpet forward away from rear door opening. (16) Extract carpet through sliding door opening (Fig. 5). INSTALLATION (1) Insert carpet through sliding door opening. (2) Roll carpet rearward toward rear door opening. (3) Roll carpet under instrument panel. (4) Install push pins fasteners through carpet and grommet into floor to attach carpet to floor in front seat area (Fig. 5). (5) Install push pins fasteners in the rear area. CAUTION: Ensure that the correct fasteners are installed in the proper locations. Damage to the fuel tank may result. Fig. 4 SEAT ESCUTCHEONS 1 - SEAT ESCUTCHEON 2 - FLOOR CARPET (6) Install floor escutcheons (Fig. 4). (7) Install the floor console trays. (Refer to 23 BODY/INTERIOR/FLOOR CONSOLE TRAY INSTALLATION) (8) Install Quarter trim panels. (9) Install D-pillar trim covers. (10) Install lower B-pillar trim covers. (11) Install rear door sill plate. (12) Install sliding door sill plates. (Refer to 23 BODY/INTERIOR/SLIDING DOOR SILL PLATE INSTALLATION) (13) Install front cowl panels and sill plates. (14) Install the passenger seats. Refer to the Owner’s Manual for proper procedures. (15) Install front center console. (16) Install front seats. (Refer to 23 - BODY/ SEATS/SEAT - INSTALLATION) COWL TRIM REMOVAL (1) Remove door sill plate. (2) Disengage hidden clips holding cowl trim to cowl panel (Fig. 1). (3) Remove cowl trim from vehicle. INSTALLATION (1) Place cowl trim panel in position on vehicle (Fig. 1). (2) Engage hidden clips attaching cowl trim to cowl panel. (3) Install door sill plate. Fig. 5 FLOOR CARPET 1 2 3 4 5 6 - CARPET LOCATOR GROMMET PUSH PIN CARPET CARPET GROMMET HEEL PROTECTOR PAD BODY ASSEMBLY C-PILLAR TRIM REMOVAL (1) Remove quarter trim panel. (2) Remove seat belt turning loop from height adjuster. (3) Remove screw attaching C-pillar trim panel to C-pillar (Fig. 6). 23 - 76 INTERIOR RS C-PILLAR TRIM (Continued) (4) Disengage hidden clips attaching trim to upper C-pillar. (5) Remove upper C-pillar trim from vehicle. Fig. 7 DOOR SILL PLATE 1 - CLIPS 2 - SLIDING DOOR SILL TRIM PLATE 3 - FRONT DOOR SILL TRIM PLATE Fig. 6 C-PILLAR 1 - C-PILLAR TRIM PANEL 2 - C-PILLAR INSTALLATION (1) Place upper C-pillar trim in position on vehicle (Fig. 6). (2) Engage hidden clips attaching trim to upper C-pillar. (3) Install screw attaching C-pillar trim panel to C-pillar. (4) Install seat belt turning loop onto height adjuster. Tighten all seat belt bolts to 39 N·m (29 ft. lbs.) torque. (5) Install quarter trim panel. DOOR SILL TRIM PLATE REMOVAL (1) Using trim stick (C-4755), disengage hidden clips holding door sill plate from door sill. (2) Remove sill plate from vehicle (Fig. 7). INSTALLATION (1) Place sill plate in position on vehicle (Fig. 7). (2) Align interlock tabs at front and rear to mating trim. (3) Engage hidden clips to hold door sill plate to door sill. HEADLINER REMOVAL (1) Remove sun visors and vanity mirrors. (2) Remove sun visor center supports. (3) If equipped, remove coat hooks. (4) If equipped, remove roof rail modules. (5) Remove A-pillar trim covers. (6) Remove B-pillar upper trim covers. (7) Remove C-pillar upper trim covers. (8) Remove D-pillar trim covers. (9) Remove liftgate opening header trim. (10) If equipped, remove overhead console screw. (11) If equipped, remove reading lamp. (12) Remove dome lamp. (13) Remove push in locking fasteners attaching headlining to rear roof header and roof bows (Fig. 8). (14) Remove wiring connections. (15) Remove headlining from roof. (16) Extract headlining through liftgate opening. INSTALLATION (1) Insert headlining through liftgate opening. (2) Place headlining in position on roof. (3) Connect wire connectors. (4) Install left sun visor support. (5) Install push in locking fasteners attaching headlining to rear roof header and bows (Fig. 8). (6) Install right sun visor support. (7) Install sun visors and vanity mirrors. (8) If equipped, install roof rail modules. (9) If equipped, install coat hooks. (10) Install dome lamp. (11) If equipped, install reading lamp. INTERIOR RS 23 - 77 HEADLINER (Continued) (5) Engage hidden clips attaching trim to D-pillar. (6) Install bolt attaching second row seat belt lower anchor to quarter on short wheel base vehicle. Tighten all seat belt bolts to 39 N·m (29 ft. lbs.). (7) Install second row seat belt turning loop on long wheel base vehicle. (8) Install liftgate sill plate. (9) Install rear header trim cover. LIFTGATE SILL PLATE REMOVAL (1) Disengage hidden clips holding sill plate to liftgate door opening sill (Fig. 9). (2) Remove sill plate from vehicle. Fig. 8 HEADLINING 1 - ROOF 2 - OVERHEAD CONSOLE BRACKET 3 - HEADLINING ASSEMBLY (12) (13) (14) (15) (16) (17) If equipped, install overhead console. Install liftgate opening header trim. Install D-pillar trim covers. Install C-pillar upper trim covers. Install B-pillar upper trim covers. Install A-pillar trim covers. LEFT D-PILLAR TRIM PANEL REMOVAL (1) Remove rear header trim cover. (2) Remove liftgate sill plate. (3) Remove second row seat belt turning loop on long wheel base vehicle. (4) Remove bolt attaching second row seat belt lower anchor to quarter on short wheel base vehicle. (5) Disengage hidden clips attaching trim to D-pillar. (6) Disconnect speaker wire connector, if equipped. (7) Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle. (8) Remove D-pillar trim from vehicle. INSTALLATION (1) Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle. (2) Position D-pillar trim panel on vehicle. (3) Connect speaker wire connector to speaker, if equipped. (4) Align locating pins on backside of trim panel to mating holes in inner quarter panel. Fig. 9 LIFTGATE SILL PLATE 1 - LIFTGATE SILL PLATE 2 - LIFTGATE SILL INSTALLATION (1) Place sill plate in position on vehicle. (2) Align engage hook tabs at end of liftgate sill plate to D-pillar trim. (3) Engage hidden clips to hold sill plate to liftgate door opening sill. QUARTER TRIM BOLSTER REMOVAL The speaker grille in the quarter trim panel is not removable. The trim panel must be removed to service the speaker. (1) Disengage hidden clips attaching trim bolster to quarter trim panel. (2) Remove quarter trim panel from vehicle. INSTALLATION The speaker grille in the quarter trim bolster is not removable. The trim bolster must removed to service the speaker. (1) Place quarter trim bolster in position on vehicle. 23 - 78 INTERIOR RS QUARTER TRIM BOLSTER (Continued) (2) Engage hook retainer attaching front of trim bolster to quarter trim panel, if applicable. (3) Engage hidden clips attaching trim bolster to quarter trim panel. RIGHT QUARTER TRIM PANEL REMOVAL CAUTION: Disconnect the battery negative cable. Damage to accessory feed circuit can result. (1) Remove first row seat. (2) Remove second row seat. (3) Remove sliding door sill trim panel. (4) Remove quarter trim bolster. (5) Remove D-pillar trim panel. (6) Remove first row seat belt anchor. (7) Remove second row seat belt anchor. (8) Remove screws attaching quarter trim to quarter panel from bolster area. (9) Remove screws attaching rear edge of quarter trim to attaching bracket. (10) Disengage hidden clips attaching front of quarter trim to quarter panel rearward of sliding door opening and at locators. (11) Remove quarter trim from quarter panel. (12) Disconnect speaker wire connector on LWB quarter trim panel with rear air conditioning. (13) Pass second row seat belt through slot in trim panel on long wheel base vehicle. (14) Pass first row seat belt through slot in trim panel. (15) Remove quarter trim panel from vehicle. INSTALLATION (1) Position quarter trim panel on vehicle. (2) Pass first row seat belt through slot in trim panel. (3) Pass second row seat belt through access hole in trim panel on long wheel base vehicle. (4) Connect wire connector into speaker on LWB with rear air conditioning. (5) Align locating pins on backside of trim panel to mating holes in inner quarter panel. (6) Engage hidden clips attaching front of quarter trim to quarter panel rearward of sliding door opening and at locators. (7) Install screws attaching rear edge of quarter trim to attaching bracket. (8) Install screws attaching quarter trim to inner quarter panel in bolster area. (9) Install second row seat belt anchor on long wheel base vehicle. Tighten all seat belt bolts to 39 N·m (29 ft. lbs.) torque. (10) Install first row seat belt anchor. (11) (12) (13) (14) (15) (16) (17) Install D-pillar trim panel. Install C-pillar trim panel. Install quarter trim bolster. Install sliding door sill trim panel. Install second row seat, if equipped. Install first row seat. Connect the battery negative cable. LEFT QUARTER TRIM PANEL REMOVAL CAUTION: Disconnect the negative cable clamp from battery post. Damage to accessory feed circuit can result. (1) Remove first row seat. (2) Remove second row seat, if equipped. (3) Remove front door sill plate on three door vehicle. (4) Remove sliding door sill plate on four door vehicle. (5) Remove left quarter trim bolster. (6) Remove C-pillar trim panel. (7) Remove left D-pillar trim panel. (8) Remove first row seat belt anchor. (9) Remove second row seat belt anchor on long wheel base vehicle. (10) Remove screws attaching quarter trim to quarter panel from bolster area. (11) Remove screws attaching rear edge of quarter trim to attaching bracket or inner quarter trim panel. (12) Disconnect wire connector from accessory power outlet, if equipped. (13) Remove quarter trim from quarter panel. (14) Pass front seat belt and turning loop through slot in quarter trim panel on three door vehicle. (15) Pass first row seat belt through slot in quarter trim panel. (16) Pass second row seat belt, if equipped, through slot in quarter trim panel on long wheel base vehicle. (17) Remove quarter trim panel from vehicle. INSTALLATION (1) Position quarter trim panel on vehicle. (2) Pass second row seat belt, if equipped, through slot in quarter trim panel on long wheel base vehicle. (3) Pass first row seat belt through slot in quarter trim panel. (4) Connect wire connector into accessory power outlet, if equipped. (5) Align locating pins on backside of trim panel to mating holes in inner panels. INTERIOR RS LEFT QUARTER TRIM PANEL (Continued) (6) Position quarter trim panel on inner quarter panel. (7) Install screws attaching rear edge of quarter trim to attaching bracket or inner quarter panel. (8) Install screws attaching quarter trim to inner quarter panel in bolster area. (9) Install second row seat belts anchor on long wheel base vehicle. Tighten all seat belt bolts to 39 N·m (28 in. lbs.) torque. (10) Install first row seat belt anchor. (11) Install left D-pillar trim panel. (12) Install C-pillar trim panel. (13) Install upper left B-pillar trim on three door vehicle. (14) Install left quarter trim bolster. (15) Install front door sill plate on three door vehicle. (16) Install sliding door sill plate on four door vehicle. (17) Install second row seat, if equipped. (18) Install first row seat. (19) Connect the battery negative cable. Fig. 10 REAR HEADER TRIM REAR HEADER TRIM REMOVAL 1 - REAR HEADER 2 - GUIDE PINS 3 - CLIPS (1) Disengage hidden clips holding trim to rear header (Fig. 10). (2) Separate rear header trim from vehicle. INSTALLATION (1) Place rear header trim in position on vehicle. (2) Align guide pins on trim to holes in header. (3) Engage hidden clips to hold trim to rear header. (4) Engage interlock tabs at D-pillar trim. REAR HVAC LOUVER REMOVAL (1) Using a trim stick (C-4755), pry edge of louver from bezel. (2) Remove HVAC louver from bezel. (3) Using a trim stick, pry lower edge of HVAC bezel away from headlining (Fig. 11). (4) Remove louver from vehicle. INSTALLATION (1) Place bezel in position in HVAC duct opening. (2) Push inward on bezel until clips snap in place. Verify that all four clips have been engaged to the bezel and that the bezel is flush to the headlining (3) Position HVAC louver to bezel. (4) Snap both ends of the louver into HVAC bezel. Fig. 11 REAR HVAC LOUVER 1 2 3 4 - HEVAC DUCT REAR HEVAC LOUVER HEADLINING CLIP 23 - 79 23 - 80 INTERIOR RS REAR VIEW MIRROR RIGHT D-PILLAR TRIM PANEL REMOVAL REMOVAL (1) If equipped, disconnect mirror harness connector (Fig. 12). (2) Loosen the mirror base set screw (Fig. 13). (3) Slide the mirror base upward and off the bracket. (1) Remove rear header trim cover. (2) Remove liftgate sill plate. (3) Remove second row seat belt turning loop on long wheel base vehicle. (4) Remove bolt attaching second row seat belt, anchor to quarter on short wheel base vehicle. (5) Disengage hidden clips attaching trim to D-pillar. (6) Remove D-pillar trim panel from D-pillar. (7) Disconnect speaker wire connector, if equipped. (8) Pass second row seat belt, if equipped, through slot in trim panel on short wheel base vehicle. (9) Remove D-pillar trim from vehicle. INSTALLATION Fig. 12 REAR VIEW MIRROR ASSEMBLY 1 2 3 4 5 6 - HEADLINER WIRE COVER MIRROR MIRROR ASSEMBLY WIRE CONNECTOR WINDSHIELD (1) Position D-pillar trim on vehicle. (2) Pass second row seat belt, if equipped, through slot in trim panel on short wheel base vehicle. (3) Connect speaker wire connector to speaker, if equipped. (4) Align locating pins on backside of trim panel to mating holes in D-pillar. (5) Engage hidden clips attaching trim to D-pillar. (6) Install screws attaching trim panel to attaching bracket on short wheel base vehicle. (7) Install quarter trim bolster on short wheel base vehicle. (8) Install bolt to attach second row seat belt, if equipped, anchor to quarter on short wheel base vehicle. Tighten all seat belt bolts to 39 N·m (29 ft. lbs.) torque. (9) Install second row seat belt turning loop on long wheel base vehicle. (10) Install liftgate sill plate. (11) Install rear header trim cover. SLIDING DOOR SILL PLATE Fig. 13 REAR VIEW MIRROR 1 - MIRROR 2 - WINDSHIELD INSTALLATION (1) slide (2) (3) Position the mirror base at the bracket and it downward onto the support bracket. Tighten the setscrew 1 N·m (15 in. lbs.) torque. If equipped, connect mirror harness connector. REMOVAL (1) Disengage hidden clips holding sill plate to sliding door opening sill. (2) Disengage hooks holding outside edge of sill plate to door sill (Fig. 14). (3) Remove sill plate from vehicle. INSTALLATION (1) Place sill plate in position on vehicle. (2) Engage hooks to hold outside edge of sill plate to door sill. (3) Align guide pins to holes in door sill. (4) Engage hidden clips to hold sill plate to sliding door opening sill. INTERIOR RS 23 - 81 SLIDING DOOR SILL PLATE (Continued) INSTALLATION Fig. 14 SLIDING DOOR SILL PLATE 1 2 3 4 5 - HOOKS SILL PLATE CLIPS SLIDING DOOR SILL CLIPS (5) Engage interlock tabs at lower B-pillar and quarter trim panel. All vehicles with driver and passenger side air bags must have a colored coded five Bullet point air bag warning label applied to the sun visor, verify label availability and ensure the label is installed. (1) Place sun visor in position on vehicle. (2) Connect illuminated vanity mirror wire connector into body harness. (3) Place sun visor in position on roof. (4) Install screws to hold sun visor to roof header (Fig. 15) . (5) Engage sun visor into center support. SUN VISOR SUPPORT REMOVAL (1) (2) (Fig. (3) Disengage sun visor from support. Remove screw holding support to roof header 16). Remove sun visor support from vehicle. SUN VISOR REMOVAL All vehicles with driver and passenger side air bags must have a colored coded five Bullet point air bag warning label applied to the sun visor, verify label availability and ensure the label is installed. (1) Disengage sun visor from center support. (2) Remove screws attaching sun visor to roof header (Fig. 15). (3) Remove sun visor from roof. (4) If equipped, disconnect illuminated vanity mirror wire connector from body harness. (5) Remove sun visor from vehicle. Fig. 16 SUN VISOR SUPPORT 1 - OVERHEAD CONSOLE 2 - SUN VISOR SUPPORT 3 - HEADLINING INSTALLATION (1) (2) (Fig. (3) Fig. 15 SUN VISOR 1 - HEADLINING 2 - SUN VISOR Place sun visor support in position on vehicle. Install screw holding support to roof header 16) . Engage sun visor into support. 23 - 82 INTERIOR FLOOR CONSOLE TRAY REMOVAL (1) Remove the floor console. Refer to the Owner’s Manual for proper procedures. (2) Remove the four screws and remove the tray. INSTALLATION (1) Install the floor console tray and install the screws. (2) Install the floor console. Refer to the Owner’s Manual for proper procedures. RS FLOOR CONSOLE TRAY BRACKET ASSEMBLY REMOVAL (1) Remove the floor carpet. (Refer to 23 - BODY/ INTERIOR/CARPETS AND FLOOR MATS REMOVAL) (2) Disconnect the electrical connector. (3) Remove the four screws and remove the bracket assembly. INSTALLATION (1) Install the bracket assembly and install the four screws. (2) Connect the electrical connector. (3) Install the floor carpet. (Refer to 23 - BODY/ INTERIOR/CARPETS AND FLOOR MATS INSTALLATION) PAINT RS 23 - 83 PAINT TABLE OF CONTENTS page page PAINT SPECIFICATIONS - COLOR CODE CHARTS . . 83 BASE COAT/CLEARCOAT FINISH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 83 PAINT CODE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 84 PAINTED TOUCH-UP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 84 FINESSE SANDING/BUFFING & POLISHING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 84 PAINT SPECIFICATIONS - COLOR CODE CHARTS EXTERIOR COLORS EXTERIOR COLOR DAIMLERCHRYSLER COLOR CODE EXTERIOR COLOR DAIMLERCHRYSLER COLOR CODE AQUAMARINE METALLIC CLEARCOAT XQW ONYX GREEN PEARLCOAT YJR BRIGHT SILVER METALLIC CLEARCOAT WS2 PATRIOT BLUE PEARLCOAT WB7 DARK GARNET RED PEARLCOAT XRV STEEL BLUE PEARLCOAT XBQ INFERNO RED TINTED PEARLCOAT WEL STERLING BLUE SATIN GLOW YB2 LIGHT ALMOND PEARL METALLIC CLEARCOAT ZKJ STONE WHITE CLEARCOAT SW1 INTERIOR COLORS INTERIOR COLOR DAIMLERCHRYSLER COLOR CODE INTERIOR COLOR DAIMLERCHRYSLER COLOR CODE NAVY BLUE QL TAUPE L5 SANDSTONE T5 BASE COAT/CLEARCOAT FINISH DESCRIPTION On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. 23 - 84 PAINT PAINT CODE DESCRIPTION Exterior vehicle body colors are identified on the Body Code plate. (Refer to VEHICLE DATA/VEHICLE INFORMATION/BODY CODE PLATE DESCRIPTION). The paint code is also identified on the Vehicle Safety Certification Label which is located on the drivers door shut face. The first digit of the paint code listed on the vehicle indicates the sequence of application, i.e.: P = primary coat, Q = secondary coat. The codes listed in the Color Code Chart are used for manufacturing purposes. PAINTED TOUCH-UP DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use Mopart Scratch Filler/Primer, Touch Up Paints and Clear Top Coat. (Refer to VEHICLE DATA/VEHICLE INFORMATION/BODY CODE PLATE - DESCRIPTION). WARNING: USE A OSHA APPROVED BREATHING MASK WHEN SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PERSONAL INJURY CAN RESULT. TOUCH UP PROCEDURE (1) Scrape loose paint and corrosion from inside scratch or chip. (2) Clean affected area with Mopart Tar/Road Oil Remover, and allow to dry. (3) Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet RS enough to puddle-fill the defect without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. (4) Cover the filler/primer with color touch up paint. Do not overlap touch up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch up paint to dry hard. (5) On vehicles without clearcoat, the touch up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. (6) On vehicles with clearcoat, apply clear top coat to touch up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, Step 5 can be performed on clear top coat. WARNING: AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL – BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. FINESSE SANDING/BUFFING & POLISHING DESCRIPTION Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. CAUTION: Do not remove clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. SEATS RS 23 - 85 SEATS TABLE OF CONTENTS page CHILD SEAT MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . SYNCHRONIZING CABLE ADJUSTMENT QUAD CHILD SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . HEADREST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . HEADREST SLEEVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . RECLINER HANDLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . ARMREST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . CENTER ARMREST 3 PASSENGER BENCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT SEATBACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT SEATBACK ASSIST STRAP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT SEATBACK PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT SEATBACK COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT/QUAD SEAT CUSHION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT SEAT CUSHION SIDE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT SEAT RISER - MANUAL TRACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT SEAT TRACK POWER ADJUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 . . . . 87 . . . 87 . . . . 88 . . . . 88 . . . . 88 . . . . 88 . . . . 88 . . . . 89 . . . . 89 . . . . 89 . . . . 89 . . . . 90 . . . . 90 . . . . 90 . . . . 90 . . . . 90 . . . . 90 . . . . 91 . . . . 91 . . . . 92 . . . . 92 . . . . 92 . . . . 92 . . . . 92 . . . . 92 . . . . 93 . . . . 93 . . . . 93 . . . . 94 . . . . 94 . . . . 94 page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94 FRONT SEAT TRACK MANUAL ADJUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95 FRONT SEAT TRACK - FRONT COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95 FRONT SEAT TRACK - REAR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96 QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96 QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 97 QUAD BUCKET SEAT RISER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 97 BUCKET SEAT BACK - QUAD BUCKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 98 BENCH SEATBACK PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 99 SEAT CUSHION COVER - QUAD BUCKET, 50/50 SPLIT, BENCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 100 BENCH SEAT RISER - 50/50 SPLIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 100 BENCH SEAT RISER - SECOND ROW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101 BENCH SEAT RISER - THIRD ROW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101 SEAT BACK HINGE COVERS - QUAD BUCKET, 50/50 SPLIT, BENCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101 BENCH SEAT BACK HINGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 101 SYNCHRONIZING CABLE ADJUSTMENT . . 102 23 - 86 SEATS BENCH SEAT BACK REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . BENCH SEAT BACK COVER REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . BENCH SEAT TRACK REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . PLASTIC GROCERY BAG RETAINER REMOVAL . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . RS . . . . . . . . . 102 . . . . . . . . . 103 . . . . . . . . . 103 . . . . . . . . . 103 . . . . . . . . . 103 . . . . . . . . . 104 . . . . . . . . . 104 . . . . . . . . . 104 UNDER SEAT STORAGE BIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . UNDER SEAT STORAGE BIN GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . UNDER SEAT STORAGE BIN LOCK/LATCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . LUMBAR SUPPORT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 104 . . . . 105 . . . . 105 . . . . 105 . . . . 105 . . . . 105 . . . . 106 . . . . 106 CHILD SEAT MODULE REMOVAL (1) Close child restraint seat. (2) Remove seat back cover. (3) Remove screws attaching child restraint seat module hinges to seat back frame lower rail (Fig. 1). (4) Return seat back to upright position. (5) Disengage push in fasteners attaching upper bolster to child restraint seat module (Fig. 2). (6) Remove screws attaching top of module to seat back frame upper rail (Fig. 3). (7) Remove child restraint seat module from seat back (Fig. 4). Fig. 2 CHILD RESTRAINT SEAT UPPER BOLSTER 1 - UPPER BOLSTER 2 - CHILD RESTRAINT SEAT MODULE 3 - PUSH-IN FASTENER Fig. 1 CHILD RESTRAINT SEAT LOWER HINGE 1 - CHILD RESTRAINT SEAT MODULE 2 - LOWER HINGE Fig. 3 CHILD RESTRAINT SEAT UPPER SCREWS 1 - UPPER BOLSTER 2 - CHILD RESTRAINT SEAT MODULE SEATS RS 23 - 87 CHILD SEAT MODULE (Continued) (5) Install push in fasteners attaching upper bolster to child restraint seat module (Fig. 2). (6) Return seat back to folded position. (7) Install seat back cover. (8) Verify child restraint seat operation. Fig. 5 INTERLOCK LEVER 1 2 3 4 Fig. 4 CHILD RESTRAINT SEAT MODULE 1 - 1ST REAR SEAT BACK 2 - CHILD RESTRAINT SEAT MODULE 3 - SEAT BACK HINGE INTERLOCK LEVER INSTALLATION INSTALLATION (1) Place child restraint seat module in position on seat back (Fig. 4). (2) Position seat back hinge interlock lever over the top of the outboard child restraint seat hinge (Fig. 5). (3) Install screws attaching child restraint seat module hinges to seat back frame lower rail (Fig. 1). (4) Install screws attaching top of module to seat back frame upper rail (Fig. 3). Tighten nuts to 7 N·m (62 in. lbs.) torque. - CHILD RESTRAINT SEAT HINGE SEAT BACK HINGE INTERLOCK LEVER 1ST REAR SEAT BACK SEAT BACK FRAME RAIL SYNCHRONIZING CABLE ADJUSTMENT NOTE: Bench seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. If the seat back hinges do not release at the same time the synchronizing cable must be adjusted. (1) Remove seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Disengage cable from the recline mechanism by pulling the cable end toward the front of the seat (Fig. 6). (3) Pull U-shaped locking tab on self-adjusting mehcanism to disengage auto-adjust feature. (4) Reattach self-adjusting mechanism, pulling against spring load to tighten cable. (5) Press locking tab onto the adjusting mechanism to lock into place. 23 - 88 SEATS RS CHILD SEAT MODULE (Continued) Fig. 6 SYNCHRONIZING CABLE 1 - CABLE END 2 - LOCKING TAB 3 - SETBACK HINGE QUAD CHILD SEAT REMOVAL (1) Remove the seat. Refer to Owner’s Manual for proper procedures. (2) Remove seat back cover (Fig. 7). (3) Remove fasteners attaching quad child seat to the seat (Fig. 8). (4) Remove quad child seat from the seat. Fig. 8 CHILD RESTRAINT SEAT BACK 1 - FASTENERS 2 - J-STRAPS 3 - FASTENERS INSTALLATION (1) (2) lbs.) (3) (4) Place quad child seat in position. Install fasteners and tighten to 13.5 N·m (10 ft. Install seat back cover. Install seat in vehicle. HEADREST REMOVAL (1) Lift head restraint to top of travel. (2) Depress lock button on side of sleeve at top of seat back (Fig. 9). (3) Pull head restraint from top of seat back. INSTALLATION (1) Place head restraint in position. (2) Depress lock button on side of sleeve at top of seat back. (3) Push heat restraint down into position. HEADREST SLEEVE Fig. 7 SEAT BACK COVER 1 - SEAT BACK COVER REMOVAL (1) Remove head rest. (2) Disengage closure attaching bottom of trim cover together. SEATS RS 23 - 89 HEADREST SLEEVE (Continued) Fig. 10 HEAD RESTRAINT SLEEVE RETAINER 1 - GUIDE TUBE 2 - PINCH RETAINER TO RELEASE 3 - SEAT BACK FRAME Fig. 9 HEAD RESTRAINT 1 - HEAD RESTRAINT 2 - SLEEVES 3 - LOCK BUTTON (3) Reach under trim cover through opening at bottom of seat back. (4) Pinch retainer barbs on end of head restraint sleeve together (Fig. 10). (5) Pull head restraint sleeve upward and out the top of the seat back frame guide tube (Fig. 11). INSTALLATION Fig. 11 HEAD RESTRAINT SLEEVE 1 2 3 4 - SEAT BACK FRAME HEAD RESTRAINT SLEEVE RETAINER GUIDE TUBE (1) Insert head restraint sleeve into guide tube at top of seat back. (2) Push head restraint sleeve downward until retainer clicks into lock position. (3) Engage closure to hold bottom of trim cover together. (4) Install head restraint. (1) Place recliner handle in position on spline shaft. (2) Install screw to hold recliner handle to recliner spline shaft (Fig. 12). RECLINER HANDLE ARMREST REMOVAL (1) Remove screw holding recliner handle recliner spline shaft (Fig. 12). (2) Remove recliner handle from spline shaft. to INSTALLATION REMOVAL (1) Using a small flat blade, pry cap from side of armrest (Fig. 13). (2) Remove bolt attaching armrest to seat back. 23 - 90 SEATS RS ARMREST (Continued) (2) Install bolt attaching armrest to seat back. Tighten bolt to 29N·m (21 ft. lbs.) torque. (3) Install side cap into the side of the armrest. CENTER ARMREST 3 PASSENGER BENCH REMOVAL Fig. 12 RECLINER HANDLE - MANUAL 1 2 3 4 - CUSHION SIDE COVER RECLINER SPLINE SCREW RECLINER HANDLE (3) Remove armrest from seat back. (1) Remove screws attaching the plastic grocery bag retainer. (Refer to 23 - BODY/SEATS/PLASTIC GROCERY BAG RETAINER - REMOVAL) (2) Remove seat back rear cover. (3) Remove E-clip from pivot post. (4) Remove pivot post. (5) Remove armrest. (6) Remove pivot bushings. INSTALLATION (1) Install pivot bushings. (2) Place armrest in position. (3) Install pivot post. (4) Install E-clip to pivot post. (5) Install seat back rear cover. (6) Install screws attaching the plastic grocery bag retainer. (Refer to 23 - BODY/SEATS/PLASTIC GROCERY BAG RETAINER - INSTALLATION) FRONT SEAT REMOVAL (1) From under vehicle, remove nuts attaching front seat risers to the floor. (2) Remove seat and riser from floor (Fig. 14). (3) Tip seat rearward and disconnect wire connectors from body harness, if equipped. (4) Remove seat from vehicle. INSTALLATION Fig. 13 ARMREST 1 2 3 4 5 6 - SEAT BACK - ARMREST - SHOULDER BOLT - CAP - WASHER - STOP SCREW INSTALLATION (1) Place armrest in position on seat back. (1) Place seat into position (2) Tip seat rearward and connect wire connectors to body harness, if equipped. (3) Place seat and riser into floor. (4) From under vehicle, install nuts attaching front seat risers to the floor. Tighten nuts to 60 N·m (44 ft. lbs.) torque. FRONT SEATBACK REMOVAL NOTE: On front seats equipped with side air bags, the seatback is serviced as an assembly. SEATS RS 23 - 91 FRONT SEATBACK (Continued) Fig. 14 FRONT SEAT 1 - FRONT SEAT 2 - CONNECTORS 3 - B-PILLAR (1) Remove head rest sleeves. (Refer to 23 - BODY/ SEATS/HEADREST SLEEVE - REMOVAL) (2) Remove the armrest. (Refer to 23 - BODY/ SEATS/ARMREST - REMOVAL) (3) Remove the seatback recliner lever. (4) Remove the lumbar adjustment lever. (5) Remove both seat cushion side covers. (Refer to 23 - BODY/SEATS/FRONT SEAT CUSHION SIDE COVER - REMOVAL) (6) Remove nut attaching the recliner to the seatback frame (Fig. 15). (7) Remove both pivot bolts and remove seatback from recliner. INSTALLATION (1) Place seat back into position. (2) Install both pivot bolts attaching seat back frame to seat track. Tighten bolts to 54 N·m (40 ft. lbs.) torque. (3) Install nut attaching the recliner to the seat back frame. Tighten nut to 12 N·m (105 in. lbs.) torque. (4) Install both seat cushion side covers. (Refer to 23 - BODY/SEATS/FRONT SEAT CUSHION SIDE COVER - INSTALLATION) (5) Install the lumbar adjustment lever. (6) Install the seat back recliner lever. (7) Install the armrest. (Refer to 23 - BODY/ SEATS/ARMREST - INSTALLATION) (8) Install headrest sleeves. (Refer to 23 - BODY/ SEATS/HEADREST SLEEVE - INSTALLATION) Fig. 15 FRONT SEATBACK FRONT SEATBACK ASSIST STRAP REMOVAL (1) Using a small screw driver, pry screw plugs from ends of assist strap (Fig. 16). (2) Remove screws attaching assist strap to seatback. (3) Remove assist strap from vehicle. Fig. 16 FRONT SEATBACK ASSIST STRAP 1 - ASSIST STRAP 2 - SCREW PLUG 3 - SEAT BACK 23 - 92 SEATS RS FRONT SEATBACK ASSIST STRAP (Continued) INSTALLATION (1) Place assist strap in position on vehicle. (2) Install screws attaching assist strap to seat back. Tighten screws to 2.5 N·m (22 in. lbs.). (3) Insert screw plugs into ends of assist strap (Fig. 16). FRONT SEATBACK PANEL REMOVAL (1) Remove the screws (Fig. 17). (2) Tip the top of the panel away from the seat back and lift off the hooks at the bottom to remove. FRONT SEATBACK COVER REMOVAL NOTE: On vehicles equipped with seat side air bags the seat cover is NOT serviceable. The seat back is serviced as an assembly. (Refer to 23 - BODY/ SEATS/SEAT BACK - REMOVAL) (1) Remove the seat back. (Refer to 23 - BODY/ SEATS/FRONT SEATBACK - REMOVAL) (2) Unclip J-straps as necessary. (3) Remove seat back cover from seat back cushion and frame assembly. INSTALLATION NOTE: On vehicles equipped with seat side air bags the seat cover is NOT serviceable. The seat back is serviced as an assembly only. (Refer to 23 - BODY/ SEATS/SEAT BACK - INSTALLATION) (1) Fit seat cover onto seat back cushion and frame assembly. (2) Connect the J-straps. (3) Install the seat back. (Refer to 23 - BODY/ SEATS/FRONT SEATBACK - INSTALLATION) FRONT/QUAD SEAT CUSHION REMOVAL Fig. 17 FRONT SEATBACK PANEL - TYPICAL 1 - SCREWS 2 - SEAT BACK PANEL 3 - SEAT BACK INSTALLATION (1) Place seat back cover onto the seat and engage the bottom hooks. (2) Install the top screws. (1) Remove seat cushion side covers, and leave connector connected, if equipped. (Refer to 23 BODY/SEATS/FRONT SEAT CUSHION SIDE COVER - REMOVAL) (2) On quad buckets, remove the seat side shield and cup holder. (Refer to 23 - BODY/SEATS/SEAT SIDE SHIELD/QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER - REMOVAL) and (Refer to 23 - BODY/SEATS/QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER - REMOVAL) (3) Remove seat track front and rear covers if equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK REAR COVER - REMOVAL) and (Refer to 23 BODY/SEATS/SEAT TRACK FRONT COVER REMOVAL) SEATS RS 23 - 93 FRONT/QUAD SEAT CUSHION (Continued) (4) If equipped, open stowage bin to access front pan bolts. (5) Remove bolts attaching seat cushion pan to seat track. (6) Disconnect wire connectors, if equipment. (7) Remove seat cushion from seat. (8) Disengage J-strap retainers holding seat cover to cushion. (9) Remove seat cushion pan from cover and pad. INSTALLATION (1) Place seat cushion cover in position on seat cushion. (2) Engage J-strap retainers to hold seat cover to cushion. (3) Place seat cushion in position on seat. (4) Connect wire connectors, if equipment. (5) Install bolts attaching seat cushion to seat track. Tighten bolts to 28.5 N·m (21 ft. lbs.) torque. (6) If equipped, close stowage bin. (7) Install seat track front and rear covers, if equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK REAR COVER - INSTALLATION) and (Refer to 23 BODY/SEATS/SEAT TRACK FRONT COVER INSTALLATION) (8) Install the quad seat side shield and cup holder if equipped. (Refer to 23 - BODY/SEATS/QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER INSTALLATION) and (Refer to 23 - BODY/SEATS/ QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER - INSTALLATION) (9) Install seat cushion side covers. (Refer to 23 BODY/SEATS/FRONT SEAT CUSHION SIDE COVER - INSTALLATION) FRONT SEAT CUSHION SIDE COVER REMOVAL (1) Remove screws and plastic push pin attaching seat cushion side cover to bucket seat (Fig. 18). (2) Disengage J-strap along rear of seat cushion to access screw. (3) Remove screw attaching rear of side cover to seat cushion frame. (4) Remove side cover from seat cushion. (5) If equipped, disconnect wire connector from power seat switch (Fig. 19). Fig. 18 FRONT SEAT SIDE SHIELD 1 - SCREWS 2 - SIDE SHIELD 3 - SEAT CUSHION Fig. 19 POWER SEAT SWITCH WIRE CONNECTOR 1 - SEAT CUSHION SIDE COVER 2 - POWER SEAT SWITCH 3 - WIRE CONNECTOR INSTALLATION (1) Place side cover in position on seat cushion. (2) If equipped, connect wire connector into power seat switch. (3) Install screw attaching rear of side cover to seat cushion frame. Tighten screw to 1 N·m (9 in. lbs.) torque. (4) Engage J-strap along rear of seat cushion to access screw. (5) Install screws attaching seat cushion side cover to bucket seat (Fig. 18). 23 - 94 SEATS RS FRONT SEAT RISER - MANUAL TRACK FRONT SEAT TRACK POWER ADJUSTER REMOVAL REMOVAL (1) Remove seat from vehicle. (Refer to 23 - BODY/ SEATS/FRONT SEAT - REMOVAL) (2) Remove storage bin from riser. (Refer to 23 BODY/SEATS/UNDER SEAT STORAGE BIN REMOVAL) (3) Remove nuts attaching riser to manual seat track (Fig. 20). (4) Remove riser from seat. The power seat track and motors are serviced as an assembly. (1) Remove seat from vehicle. (Refer to 23 - BODY/ SEATS/FRONT SEAT - REMOVAL) (2) Remove seat cushion. (Refer to 23 - BODY/ SEATS/FRONT/QUAD SEAT CUSHION REMOVAL) (3) Remove nut attaching recliner to seat back frame. (4) Remove bolts attaching seat back frame to seat track. (5) Remove stud on seat back frame from recliner. (6) Remove seat back. (7) If power seat track is being replaced, transfer power recliner, wire harness and trim covers to replacement seat track. INSTALLATION Fig. 20 FRONT SEAT RISER - MANUAL TRACK 1 - RISER 2 - SEAT TRACK INSTALLATION (1) Place riser in position on seat. (2) Install nuts attaching riser to manual seat track (Fig. 20). Tighten fasteners to 81 N·m (60 ft. lbs.) torque. (3) If equipped, install storage bin into riser. (Refer to 23 - BODY/SEATS/UNDER SEAT STORAGE BIN - INSTALLATION) (4) Install seat into vehicle. Tighten fasteners to 54 N·m (40 ft. lbs.) torque. (Refer to 23 - BODY/ SEATS/FRONT SEAT - INSTALLATION) The power seat track and motors are serviced as an assembly. (1) Install wire harness. (2) Place seat back in position. (3) Insert stud on seat back frame into recliner. (4) Install bolts to hold seat back frame to seat track. (5) Install nut attaching recliner to seat back frame. (6) Install seat cushion. (Refer to 23 - BODY/ SEATS/FRONT/QUAD SEAT CUSHION - INSTALLATION) (7) Install seat in vehicle. Tighten fasteners to 60 N·m (44 ft. lbs.) torque. (Refer to 23 - BODY/SEATS/ FRONT SEAT - INSTALLATION) FRONT SEAT TRACK MANUAL ADJUSTER REMOVAL (1) Remove seat from vehicle. (Refer to 23 - BODY/ SEATS/FRONT SEAT - REMOVAL) (2) Remove seat cushion. (Refer to 23 - BODY/ SEATS/FRONT/QUAD SEAT CUSHION REMOVAL) (3) Remove riser. (Refer to 23 - BODY/SEATS/ FRONT SEAT RISER - MANUAL TRACK REMOVAL) SEATS RS 23 - 95 FRONT SEAT TRACK MANUAL ADJUSTER (Continued) (4) Remove bolt attaching seat back frame to seat track (Fig. 21). (5) Remove seat track from seat adjuster handle (Fig. 22). (6) Remove seat track from seat. INSTALLATION (1) Place seat track in position on seat. (2) Place adjuster handle in position on seat track (Fig. 22). (3) Insert stud on seat back frame into recliner. (4) Install bolt attaching seat back frame to seat track (Fig. 21). (5) Install riser. (Refer to 23 - BODY/SEATS/ FRONT SEAT RISER - MANUAL TRACK - INSTALLATION) (6) Install seat cushion. (Refer to 23 - BODY/ SEATS/FRONT/QUAD SEAT CUSHION - INSTALLATION) (7) Install seat in vehicle. (Refer to 23 - BODY/ SEATS/FRONT SEAT - INSTALLATION) FRONT SEAT TRACK - FRONT COVER Fig. 21 FRONT SEAT TRACK - MANUAL 1 - SHOULDER BOLT 2 - RECLINER 3 - MANUAL SEAT TRACK Fig. 22 FRONT SEAT TRACK ADJUSTER HANDLE 1 - RECLINER 2 - SEAT ADJUSTER HANDLE 3 - MANUAL SEAT TRACK REMOVAL (1) Remove screws attaching front cover to seat track (Fig. 23). (2) Remove front cover from vehicle. Fig. 23 FRONT SEAT TRACK FRONT COVER MANUAL DRIVERS SEAT 1 - SCREWS 2 - COVER 3 - SEAT CUSHION INSTALLATION (1) Place front cover in position on seat. (2) Install screws attaching front cover to seat track (Fig. 23). Tighten screws to 4 N·m (35 in. lbs.) torque. 23 - 96 SEATS FRONT SEAT TRACK - REAR COVER REMOVAL RS (5) Depress the tab on the cup holder assembly (Fig. 27). (6) Using a deep well socket or equivalent, depress the push pin tabs and remove the cup holder assembly (Fig. 28). (1) Disengage arrowhead retainer from loop strip attaching rear cover to power seat track crossbar (Fig. 24). (2) Disengage fasteners attaching rear cover to slots on power seat track. (3) Remove rear cover from seat. Fig. 25 SEAT SIDE SHIELD/CUP HOLDER 1 2 3 4 - HINGE COVER SCREWS HINGE COVER DUMP LATCH HANDLE SIDE SHIELD/CUP HOLDER Fig. 24 FRONT POWER SEAT TRACK - REAR COVER 1 - PUSH IN FASTENER 2 - POWER SEAT TRACK REAR COVER 3 - POWER SEAT TRACK INSTALLATION (1) Place rear cover in position on seat. (2) Engage fasteners attaching rear cover to slots on power seat track. (3) Engage arrowhead retainer into loop strip attaching rear cover to power seat track crossbar (Fig. 24) . Fig. 26 SEAT SIDE SHIELD/CUP HOLDER SCREWS QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER REMOVAL (1) Remove the seat from the vehicle. Refer to Owner’s Manual for proper procedures. (2) Remove the two screws and remove the hinge cover (Fig. 25) (3) Remove the dump latch handle. (4) Remove the three screws (Fig. 26). 1 - SIDE SHIELD/CUP HOLDER SCREWS 2 - SIDE SHIELD/CUP HOLDER INSTALLATION (1) Install cup holder onto the pin and lock tab. (2) Install the three screws. (3) Install the dump latch handle. (4) Install the hinge cover and screws. (5) Install the seat. Refer to Owner’s Manual for proper procedures. SEATS RS 23 - 97 QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER (Continued) QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER REMOVAL (1) Remove the three screws (Fig. 29). (2) Remove the side shield. Fig. 27 SIDE SHIELD/CUP HOLDER ATTACHMENT CLIPS 1 - SIDE SHIELD/CUP HOLDER 2 - LOCK TAB 3 - SEAT RISER Fig. 29 SEAT SIDE COVER - QUAD BUCKETS 1 - SIDE SHIELD SCREWS 2 - SIDE SHIELD INSTALLATION (1) Install the side shield hook into the rectangular hole on the riser. (2) Install the three screws. QUAD BUCKET SEAT RISER REMOVAL Fig. 28 SIDE SHIELD/CUP HOLDER ATTACHMENT PIN 1 - SEAT RISER 2 - ATTACHMENT PIN 3 - SIDE SHIELD/CUP HOLDER (1) Remove the seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Remove seat side shield/cupholder. (Refer to 23 - BODY/SEATS/QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER - REMOVAL) (3) Remove the seat side shield. (Refer to 23 BODY/SEATS/QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER - REMOVAL) (4) Remove the five bolts, two nuts, strut bushing and remove the riser from the seat (Fig. 30). INSTALLATION (1) Install the riser, the strut bushing into the hole, the five bolts, two nuts and tighten all fasteners to 40 N·m (30 ft. lbs.). (2) Install the seat side shield. (Refer to 23 BODY/SEATS/QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER - INSTALLATION) 23 - 98 SEATS RS QUAD BUCKET SEAT RISER (Continued) Fig. 30 BUCKET SEAT RISER - QUAD BUCKET 1 2 3 4 - SEAT SIDE SHIELD/CUP HOLDER SEAT RISER SEAT SIDE SHIELD RISER BOLTS (3) Install the seat side shield/cup holder. (Refer to 23 - BODY/SEATS/QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER - INSTALLATION) (4) Install the seat. Refer to Owner’s Manual for proper procedures. Fig. 31 QUAD SEAT SYNCHRONIZER CABLE 1 - CABLE END CONNECTOR 2 - SYNCHRONIZER CABLE 3 - SEATBACK HINGE BUCKET SEAT BACK - QUAD BUCKET REMOVAL NOTE: Quad seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. (1) Remove the headrests. (Refer to 23 - BODY/ SEATS/HEADREST - REMOVAL) (2) Remove the armrests, if equipped. (Refer to 23 - BODY/SEATS/ARMREST - REMOVAL) (3) Remove the seatback hinge covers. (Refer to 23 - BODY/SEATS/SEAT BACK HINGE COVERS QUAD BUCKET, 50/50 SPLIT, BENCH - REMOVAL) (4) Disconnect the child seat synchronizer cable, if equipped. (Fig. 31) (5) Remove the seatback frame bolts and remove the seat back. (Fig. 32) INSTALLATION (1) Install the seatback. (2) Install the shoulder bolts attaching the seatback hinge to the seat back frame and tighten to 34 N·m (25 ft. lbs.) torque. Fig. 32 SEAT BACK HINGE - TYPICAL 1 - SEATBACK FRAME BOLTS 2 - SEAT CUSHION FRAME BOLTS 3 - SEATBACK HINGE (3) Connect the child seat synchronizer cable, if equipped. (4) Install the seatback hinge covers. (Refer to 23 BODY/SEATS/SEAT BACK HINGE COVERS QUAD BUCKET, 50/50 SPLIT, BENCH - INSTALLATION) (5) Install the armrests. (Refer to 23 - BODY/ SEATS/ARMREST - INSTALLATION) SEATS RS 23 - 99 BUCKET SEAT BACK - QUAD BUCKET (Continued) (6) Install the headreast. (Refer to 23 - BODY/ SEATS/HEADREST - INSTALLATION) (7) Verify seatback operation. BENCH SEATBACK PANEL REMOVAL (1) On third row seats remove plastic grocery bag retainer. (Refer to 23 - BODY/SEATS/PLASTIC GROCERY BAG RETAINER - REMOVAL) (2) Using a fork type prying tool (C4829) on three pass seats, disengage push-in fasteners holding seat back cover to seat back frame and remove seat back cover from seat. (Fig. 33). (3) Using a fork type prying tool (C4829) on two pass seats, disengage push-in fasteners holding the upper corners and lower edge of the seat back panel to seat back frame and remove seat back cover from seat by pulling the lower edge out away from the seatback to disengage the upper two hooks. (Fig. 34). Fig. 34 TWO - PASSENGER BENCH SEATBACK PANEL 1 - SEATBACK REAR PANEL 2 - SEATBACK SEAT CUSHION COVER QUAD BUCKET, 50/50 SPLIT, BENCH REMOVAL BENCH SEAT & 50/50 SPLIT Fig. 33 THREE - PASS BENCH SEATBACK PANEL 1 - SEATBACK REAR PANEL 2 - FIRST REAR CHILD RESTRAINT SEAT INSTALLATION (1) On three pass seats place seat back panel in position on seat and install the push-in fasteners (Fig. 33). (2) On two pass seats engage the two upper hooks of the panel, place the panel into position and install the push-in fasteners (Fig. 34). (3) On third row bench seats install grocery bag holder. (Refer to 23 - BODY/SEATS/PLASTIC GROCERY BAG RETAINER - INSTALLATION) (1) Remove seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Remove seat back. (Refer to 23 - BODY/SEATS/ BENCH SEAT BACK - REMOVAL) (3) Remove seat risers. (Refer to 23 - BODY/ SEATS/BENCH SEAT RISER - 50/50 SPLIT REMOVAL) and (Refer to 23 - BODY/SEATS/BENCH SEAT RISER - FIRST ROW - REMOVAL) and (Refer to 23 - BODY/SEATS/BENCH SEAT RISER - SECOND ROW - REMOVAL) (4) Disconnect the cushion cover J-straps. (5) Remove seat cushion cover from seat cushion. QUAD BUCKET (1) Remove seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Remove seat back.(Refer to 23 - BODY/SEATS/ BUCKET SEAT BACK - QUAD BUCKET REMOVAL) (3) Remove seat risers. (Refer to 23 - BODY/ SEATS/QUAD BUCKET SEAT RISER - REMOVAL) (4) Disconnect the cushion cover J-straps. (5) Remove seat cushion cover from seat cushion. 23 - 100 SEATS RS SEAT CUSHION COVER - QUAD BUCKET, 50/50 SPLIT, BENCH (Continued) INSTALLATION BENCH SEAT & 50/50 SPLIT (1) Position the seat cushion cover on the cushion. (2) Engage the J-strap retainers. (3) Steam wrinkles from seat cushion, if necessary. (4) Install seat risers. (Refer to 23 - BODY/SEATS/ BENCH SEAT RISER - 50/50 SPLIT - INSTALLATION) and (Refer to 23 - BODY/SEATS/BENCH SEAT RISER - SECOND ROW - INSTALLATION) and (Refer to 23 - BODY/SEATS/BENCH SEAT RISER - THIRD ROW - INSTALLATION) (5) Install seat back. (Refer to 23 - BODY/SEATS/ BENCH SEAT BACK - INSTALLATION) (6) Install seat into vehicle. QUAD BUCKET (1) Position the seat cushion cover on the cushion. (2) Engage the J-strap retainers. (3) Steam wrinkles from seat cushion, if necessary. (4) Install seat risers. (Refer to 23 - BODY/SEATS/ QUAD BUCKET SEAT RISER - INSTALLATION) (5) Install seat back. (Refer to 23 - BODY/SEATS/ BUCKET SEAT BACK - QUAD BUCKET - INSTALLATION) (6) Install seat into vehicle. BENCH SEAT RISER - 50/50 SPLIT Fig. 35 BENCH SEAT RISER - 50/50 SPLIT 1 - SEAT CUSHION COVER CLIP 2 - SEAT RISER BOLTS 3 - SEAT RISER (4) Remove riser from seat. REMOVAL (1) Remove the seat from the vehicle. Refer to the Owners Manual for proper procedures. (2) Unclip the seat cushion cover j-strap. (Fig. 35). (3) Remove the six bolts and remove the riser. INSTALLATION (1) Place the riser onto the seat install the bolts and tighten to 48 N·m (35 ft. lbs.) torque. (2) Clip seat cusion cover j-strap onto the riser. (3) Install the seat into the vehicle. Refer to the Owner’s Manual for proper procedure. BENCH SEAT RISER - SECOND ROW REMOVAL (1) Remove seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Place seat bottom side up on a clean covered work surface. (3) Remove bolts attaching seat riser to seat cushion frame (Fig. 36). Fig. 36 BENCH SEAT RISER - SECOND ROW 1 - RISER 2 - FIRST ROW BENCH SEAT 3 - RISER BOLTS SEATS RS 23 - 101 BENCH SEAT RISER - SECOND ROW (Continued) INSTALLATION (1) Place riser in position on seat. (2) Install bolts attaching seat riser to seat cushion frame (Fig. 36). Tighten bolts to 48 N·m (35 ft. lbs.) torque. (3) Install seat into vehicle. BENCH SEAT RISER - THIRD ROW REMOVAL (1) Remove seat track. (Refer to 23 - BODY/ SEATS/BENCH SEAT TRACK - REMOVAL) (2) Remove bolts attaching riser to seat cushion frame and remove the riser. (Fig. 41). INSTALLATION (1) Place riser in position on seat. (2) Install bolts attaching riser to seat cushion frame (Fig. 41). Tighten nuts to 48 N·m (35 ft. lbs.) torque. (3) Install seat track. (Refer to 23 - BODY/SEATS/ BENCH SEAT TRACK - INSTALLATION) SEAT BACK HINGE COVERS QUAD BUCKET, 50/50 SPLIT, BENCH REMOVAL (1) Remove seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Remove screws attaching upper hinge cover to seat back hinge (Fig. 37). (3) Remove upper cover from seat back hinge. (4) Remove screws attaching lower cover to seat back hinge. (5) Remove lower cover from hinge. INSTALLATION (1) Place upper cover in position on seat back hinge. (2) Install screws attaching upper hinge cover to seat back hinge. Tighten screws to 2.3 N·m (20 in. lbs.) torque. (3) Place lower cover in position on hinge. (4) Install screws attaching lower cover to seat back hinge (Fig. 37). Tighten screws to 2.3 N·m (20 in. lbs.) torque. (5) Install seat in vehicle. Fig. 37 BENCH SEAT BACK HINGE COVERS TYPICAL 1 2 3 4 - UPPER COVER SCREWS LOWER COVER LOWER COVER SCREWS UPPER COVER BENCH SEAT BACK HINGE REMOVAL NOTE: Bench seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. (1) Remove the bench seat back upper and lower hinge covers. (Refer to 23 - BODY/SEATS/SEAT BACK HINGE COVERS - 50/50 SPLIT, BENCH REMOVAL) (2) Remove the seat back. (Refer to 23 - BODY/ SEATS/BENCH SEAT BACK - REMOVAL) (3) Remove bolts attaching seat back hinge to seat cushion frame (Fig. 38). (4) Remove seat back hinge from seat. (5) Remove hinge from seat. INSTALLATION INSTALLATION NOTE: Bench seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. (1) Place hinge in position on seat. (2) Engage synchronizing cable end into (clip on left side) hinge latch release arm. 23 - 102 SEATS RS BENCH SEAT BACK HINGE (Continued) (4) Reattach self-adjusting mechanism, pulling against spring load to tighten cable. (5) Press locking tab onto the adjusting mechanism to lock into place. Fig. 38 BENCH SEAT BACK HINGE 1 - SEATBACK FRAME BOLTS 2 - SEAT CUSHION FRAME BOLTS 3 - SEATBACK HINGE (3) Engage synchronizing cable housing into seat back hinge. (4) Place seat back hinge in position on seat. (5) Install bolts attaching seat back hinge to seat cushion frame. Tighten bolts to 48 N·m (35 ft. lbs.) torque. (6) Install shoulder bolts attaching seat back hinge to seat back frame (Fig. 38). Tighten nuts to 34 N·m (25 ft. lbs.) torque.(Refer to 23 - BODY/SEATS/ BENCH SEAT BACK - INSTALLATION) (7) Install bench seat back hinge covers. (Refer to 23 - BODY/SEATS/SEAT BACK HINGE COVERS 50/50 SPLIT, BENCH - INSTALLATION) (8) Verify seat back hinge operation and adjust synchronizing cable, if equipped. (Refer to 23 BODY/SEATS/SYNCHRONIZING CABLE ADJUSTMENT) SYNCHRONIZING CABLE ADJUSTMENT NOTE: Bench seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. If the seat back hinges do not release at the same time the synchronizing cable must be adjusted. (1) Remove seat from vehicle. Refer to Owner’s Manual for proper procedures. (2) Disengage cable from the recline mechanism by pulling the cable end toward the front of the seat (Fig. 39). (3) Pull U-shaped locking tab on self-adjusting mehcanism to disengage auto-adjust feature. Fig. 39 SYNCHRONIZING CABLE 1 - CABLE END 2 - LOCKING TAB 3 - SETBACK HINGE BENCH SEAT BACK REMOVAL NOTE: Bench seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. (1) Remove the headrests. (Refer to 23 - BODY/ SEATS/HEADREST - REMOVAL) (2) Remove the armrests, if equipped. (Refer to 23 - BODY/SEATS/ARMREST - REMOVAL) (3) Remove the upper hinge cover. (Refer to 23 BODY/SEATS/SEAT BACK HINGE COVERS REMOVAL) (4) Disengage synchronizing cable housing from seat back hinge, if equipped. (5) Disengage synchronizing cable end from (clip on left side) hinge latch release arm, if equipped. (6) Remove shoulder bolts attaching seat back hinge to seat back frame (Fig. 40). (7) Remove the seat back. SEATS RS 23 - 103 BENCH SEAT BACK (Continued) INSTALLATION (1) Install seat back cover onto the seat back frame and cushion assembly. (2) Connect the J-straps. (3) Install the bench seatback panel. (Refer to 23 BODY/SEATS/BENCH SEATBACK PANEL INSTALLATION) (4) Install the seat back. (Refer to 23 - BODY/ SEATS/BENCH SEAT BACK - INSTALLATION) BENCH SEAT TRACK REMOVAL Fig. 40 SEAT BACK HINGE - TYPICAL 1 - SEATBACK FRAME BOLTS 2 - SEAT CUSHION FRAME BOLTS 3 - SEATBACK HINGE INSTALLATION (1) Remove second row seat from vehicle. Refer to Owner’s Manual for proper procedure. (2) Place seat on clean covered work surface. (3) Disengage seat track adjuster link wire from track being removed. (4) Remove nuts attaching track to seat riser (Fig. 41). (5) Remove track from seat riser. NOTE: Bench seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. (1) Install the seat back. (2) Install the shoulder bolts attaching the seat back hinge to the seat back frame and tighten to 34 N·m (25 ft. lbs.) torque. (3) Connect the synchronizing cable end from (clip on left side) hinge latch release arm, if equipped. (4) Connect the synchronizing cable housing to the seat back hinge, if equipped. (5) Install the upper hinge cover. (Refer to 23 BODY/SEATS/SEAT BACK HINGE - INSTALLATION) (6) Install the armrests, if equipped. (Refer to 23 BODY/SEATS/ARMREST - INSTALLATION) (7) Install the headrest sleeves. (Refer to 23 - BODY/ SEATS/HEADREST SLEEVE - INSTALLATION) (8) Adjust synchronizing cable, if equipped. (Refer to 23 - BODY/SEATS/SYNCHRONIZING CABLE ADJUSTMENT) BENCH SEAT BACK COVER REMOVAL (1) Remove the bench seat back. (Refer to 23 BODY/SEATS/BENCH SEAT BACK - REMOVAL) (2) Remove the bench seatback panel. (Refer to 23 - BODY/SEATS/BENCH SEATBACK PANEL REMOVAL) (3) Disconnect the cover J-straps. (4) Remove the seat back cover from the seat back assembly. Fig. 41 BENCH SEAT TRACK 1 2 3 4 5 - SEAT TRACK ADJUSTER LINK RISER SEAT TRACK NUTS SEAT TRACK RISER BOLTS 23 - 104 SEATS RS BENCH SEAT TRACK (Continued) INSTALLATION (1) Place track in position on seat riser. (2) Install nuts attaching track to seat riser. (Fig. 41). Tighten nuts to 48 N·m (35 ft. lbs.) torque. (3) Engage seat track adjuster link wire onto track being installed. (4) Install second row seat into vehicle. PLASTIC GROCERY BAG RETAINER REMOVAL 3-PASS BENCH SEAT (1) Remove five screws attaching the plastic grocery bag retainer to the steel slats on the back frame (Fig. 42). (2) Remove retainer. Fig. 43 PLASTIC GROCERY BAG RETAINER - 50/50 SPLIT 1 2 3 4 5 - SEATBACK - SCREWS - SEATBACK PANEL - GROCERY BAG RETAINER - ATTACHMENT HOOKS UNDER SEAT STORAGE BIN REMOVAL Fig. 42 PLASTIC GROCERY BAG RETAINER 1 - SCREWS 2 - SCREWS (1) Release under seat storage bin latch and open bin. (2) Depress lock tabs at the rear/top edge of the storage bin (Fig. 44). (3) Pull storage bin from bucket seat riser. 50/50 SPLIT BENCH SEAT (1) Remove the screws. (Fig. 43) (2) Pull top of retainer away from the seatback and lift off of the two bottom attachment hooks. INSTALLATION 3-PASS BENCH SEAT (1) Place retainer in position. (2) Install the five attaching screws and tighten 2 N·m (17 in. lbs.) torque. 50/50 SPLIT BENCH SEAT (1) Engage bottom hooks of the retainer and place into position. (2) Install the attaching screws and tighten 2 N·m (17 in. lbs.) torque. Fig. 44 STORAGE BIN 1 2 3 4 - PASS. SIDE BUCKET SEAT UNDER SEAT STORAGE BIN RISER LOCK TAB SEATS RS 23 - 105 UNDER SEAT STORAGE BIN (Continued) INSTALLATION INSTALLATION (1) Engage storage bin tracks into guides on each side of seat riser. (2) Push storage bin inward until lock tabs snap past retaining ridge on tracks (3) Verify storage bin latch operation. (1) Place track guide in position on seat riser. (2) Install screws attaching storage bin track guide to seat riser (Fig. 45). Tighten screws to 81 N·m (32 in lbs.) torque. (3) Install under seat storage bin. (Refer to 23 BODY/SEATS/UNDER SEAT STORAGE BIN INSTALLATION) UNDER SEAT STORAGE BIN GUIDE REMOVAL (1) Remove under seat storage bin. (Refer to 23 BODY/SEATS/UNDER SEAT STORAGE BIN REMOVAL) (2) Remove screws attaching storage bin track guide to seat riser (Fig. 45). (3) Remove track guide from vehicle. Fig. 45 UNDER SEAT STORAGE BIN GUIDE 1 - STORAGE BIN TRACK GUIDE 2 - RISER UNDER SEAT STORAGE BIN LOCK/LATCH REMOVAL (1) Open under seat storage bin. (2) Remove screws holding under seat storage bin lock/latch to storage bin (Fig. 46). (3) Remove lock/latch from bin. Fig. 46 UNDER SEAT STORAGE BIN LOCK/LATCH 1 - UNDER SEAT STORAGE BIN 2 - LOCK/LATCH INSTALLATION (1) (2) (Fig. (3) Place lock/latch in position on storage bin. Install screws to hold lock/latch to storage bin 46) . Verify under seat storage bin latch operation. 23 - 106 SEATS LUMBAR SUPPORT REMOVAL (1) back (2) (3) (4) Remove screw attaching lumbar handle to seat (Fig. 47). Remove seat back assembly from cushion. Detrim the seat back assembly. Remove frame and replace. Fig. 47 LUMBAR HANDLE 1 - LUMBAR HANDLE RS INSTALLATION (1) Trim the seat back frame. (2) Install seat back assembly to cushion. (3) Install attaching screw to lumbar handle. The handle is to be installed, between two and three O’clock position. Tighten screw to 1 N·m (11 ft. lbs.) torque. (4) Test lumbar operation. STATIONARY GLASS RS 23 - 107 STATIONARY GLASS TABLE OF CONTENTS page WINDSHIELD DESCRIPTION . . . . . . . . . . . . . . . . . . . WARNING WINDSHIELD SAFETY PRECAUTIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . SLIDING DOOR GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 . . . . 107 . . . . . 107 . . . . . 108 page INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109 QUARTER WINDOW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110 REAR DOOR GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110 . . . . . 109 WINDSHIELD DESCRIPTION The windshield is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the moldings are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and moldings from the parts supplier. WARNING WINDSHIELD SAFETY PRECAUTIONS WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. URETHANE ADHESIVES ARE APPLIED AS A SYSTEM. USE GLASS CLEANER, GLASS PREP SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER AND PINCH WELD (FENCE) PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL INTEGRITY COULD BE COMPROMISED. DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND. TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNICAL DATA SHEETS, AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212. TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBLE WITH THE PARTICULAR ADHESIVE USED. BE SURE TO REFER TO THE URETHANE MANUFACTURER’S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. VAPORS THAT ARE EMITTED FROM THE URETHANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY. USE THEM IN A WELL-VENTILATED AREA. SKIN CONTACT WITH URETHANE ADHESIVE SHOULD BE AVOIDED. PERSONAL INJURY MAY RESULT. ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. REMOVAL WINDSHIELD REMOVAL – EXTERIOR METHOD The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. (1) Remove inside rear view mirror. (2) Remove windshield wiper arms. (3) Remove cowl cover. 23 - 108 STATIONARY GLASS RS WINDSHIELD (Continued) (4) Remove A-pillar trim panels. (5) Disconnect wire connectors to windshield defroster grid. (6) Place protective covers over instrument panel and hood. (7) Remove windshield molding. Using pliers, pull outward on molding at the bottom of A-pillars. (8) Using a sharp cold knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences (Fig. 1). A power cutting device can be used if available. (9) Remove windshield from vehicle. Fig. 1 CUT URETHANE AROUND WINDSHIELD 1 - COLD KNIFE 2 - WINDSHIELD senger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use. To avoid stressing the replacement windshield, the urethane bonding material on the windshield fence should be smooth and consistent to the shape of the replacement windshield . The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening. (1) Place replacement windshield into windshield opening and position glass in the center of the opening against the compression spacers. (2) Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass. (3) Remove replacement windshield from windshield opening. (4) Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 2). WARNING: CLEANER APPLYING ADHESION DO NOT USE SOLVENT BASED GLASS TO CLEAN WINDSHIELD BEFORE GLASS PREP AND PRIMER. POOR CAN RESULT. WINDSHIELD REMOVAL – INTERIOR METHOD (1) Remove inside rear view mirror. (2) Remove instrument panel top cover. Refer to Group 8E, Instrument Panel and Systems. (3) Remove A-pillar trim covers. (4) Disconnect wire connectors to windshield defroster grid. (5) Place protective covers over instrument panel and hood. (6) Using a reciprocating or oscillating power knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences. Refer to instructions provided with the equipment being used. (7) Remove windshield from vehicle. INSTALLATION The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the pas- (5) Clean inside of windshield with ammonia based glass cleaner and lint-free cloth. (6) Install molding to perimeter of windshield. (7) Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible. (8) Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time. (9) Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence. (10) Apply pinch weld primer 19 mm (0.75 in.) wide around the windshield fence. Allow at least three minutes drying time. (11) If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening (Fig. 3). (12) Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence. (13) With the aid of a helper, position the windshield over the windshield opening. (14) Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward until molding is flush to roof line and A-pillars (Fig. 3). STATIONARY GLASS RS 23 - 109 WINDSHIELD (Continued) (15) Clean access urethane from exterior with Mopart Super Kleen or equivalent. (16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. (17) Engage wire connectors to windshield defroster grid. (18) Install A-pillar trim panels. (19) Install cowl cover and wipers. (20) Install inside rear view mirror. (21) After urethane has cured, remove tape strips and water test windshield to verify repair. SLIDING DOOR GLASS REMOVAL The temperature of the vehicle should be at least 21° C (70° F) before removing the stationary quarter/ sliding door glass. Butyl sealer becomes more pliable at high temperatures. (1) Remove interior trim as necessary to gain access attaching locations on back of glass. (2) Remove nuts holding stationary glass to fence. (3) Using razor knife, cut butyl sealer holding glass to fence from between the mounting studs (Fig. 4). (4) Push glass from opening. Fig. 2 WORK SURFACE SET UP AND MOLDING INSTALLATION 1 - WINDSHIELD AND MOLDINGS 2 - BLOCKS Fig. 4 SLIDING DOOR STATIONARY GLASS 1 - NUMBERS INDICATE THE TIGHTENING SEQUENCE 2 - 6 mm BEAD OF BUTYL TAPE 3 - BODY SIDE/SLIDING DOOR GLASS INSTALLATION The temperature of the vehicle should be at least 21° C (70° F) before removing the stationary quarter/ sliding door glass. Butyl sealer becomes more pliable at high temperatures. The stationary glass fence should be cleaned of all old butyl sealer. (1) Apply a 6 mm (0.25 in.) butyl tape around perimeter of glass assembly encapsulation track. Ensure that the butyl tape is wrapped around the mounting studs. (2) Place the glass into the opening and insert mounting studs through holes in fence. (3) Install nuts to hold stationary glass to fence. Fig. 3 LOWER WINDSHIELD INTO POSITION 1 - WINDSHIELD 2 - COMPRESSION SPACERS CAUTION: Tighten nuts to 3.4 N·m (30 in. lbs.) torque in the sequence indicated. Do not over torque, or glass breakage may result (Fig. 4). (4) Install interior trim. (Refer to 23 - BODY/ DOORS - SLIDING/TRIM PANEL - INSTALLATION) (5) Verify alignment and flushness. 23 - 110 STATIONARY GLASS RS QUARTER WINDOW (3) Using pliers, pull outward on molding at the top and bottom of liftgate. (4) Using a sharp cold knife, cut urethane adhesive attaching the rear window to the liftgate. A power cutting device can be used if available (Fig. 1). (5) Remove rear window from vehicle. REMOVAL (1) Remove C-pillar trim. (2) Open quarter glass to vent position. (3) Disengage quarter window retainer from vent motor arm. (4) Remove nuts attaching quarter glass to C-pillar (Fig. 5). (5) Use magnetic socket to prevent dropping into the pillar. (6) Remove quarter glass from vehicle. REAR WINDOW REMOVAL – INTERIOR METHOD (1) Remove rear window wiper arm, if equipped. (2) Remove screws attaching moldings to liftgate at the sides of the rear window (Fig. 6). (3) Remove liftgate inside lamps and trim covers. (4) Remove center high mounted stop lamp. (5) Using a reciprocating or oscillating power knife, cut urethane adhesive holding the rear window to the liftgate. Refer to instructions provided with the equipment being used. (6) Remove rear window from vehicle. Fig. 5 QUARTER GLASS 1 - VENT CONTROL 2 - QUARTER GLASS 3 - CLIP INSTALLATION (1) Place quarter glass in position on vehicle. (2) Install nuts attaching quarter glass to C-pillar. (3) Engage quarter window retainer to vent motor arm. (4) Install screw attaching quarter window retainer to vent motor arm. (5) Close quarter glass. (6) Install C-pillar trim. REAR DOOR GLASS REMOVAL Refer to the Safety Precautions in this section for description of tools and adhesive systems that are recommended for use in this procedure. REAR WINDOW REMOVAL – EXTERIOR METHOD (1) Remove rear window wiper arm, if equipped. (2) Remove screws attaching moldings to liftgate at the sides of the rear window (Fig. 6). Fig. 6 REAR WINDOW SIDE MOLDINGS 1 - COMPRESSION SPACERS 2 - REAR WINDOW WITH MOLDING 3 - LIFT GATE INSTALLATION Refer to the Safety Precautions in this section for description of tools and adhesive systems that are recommended for use in this procedure. CAUTION: Open the left front door glass before installing rear window to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use. To avoid stressing the replacement rear window, the urethane bonding material on the rear window fence should be smooth and consistent to the shape of the replacement glass. STATIONARY GLASS RS 23 - 111 REAR DOOR GLASS (Continued) (1) Place replacement glass into rear window opening. (2) Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement rear window. If not, the fence must be formed to the shape of the new glass. (3) Using a grease pencil, mark the glass and liftgate in several locations to aid installation. (4) Remove replacement glass from liftgate opening. (5) Position the rear window inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 2). WARNING: CLEANER APPLYING ADHESION DO NOT USE SOLVENT BASED GLASS TO CLEAN REAR WINDOW BEFORE GLASS PREP AND PRIMER. POOR CAN RESULT. (6) Clean inside of rear window with ammonia based glass cleaner and lint-free cloth. (7) Apply molding to top and bottom of rear window. (8) Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of rear window and wipe with clean/dry lint-free cloth until no streaks are visible. (9) Apply Glass Primer 25 mm (1 in.) wide around perimeter of rear window. Allow at least three minutes drying time. (10) Apply Pinch weld Primer 19 mm (0.75 in.) wide around the rear window fence. Allow at least three minutes drying time. (11) If a low viscosity urethane adhesive is used, install compression spacers on the fence around the rear window opening (Fig. 7). (12) Apply a 10 mm (0.4 in.) bead of urethane along center line of rear window fence. (13) With the aid of a helper, position the rear window over the rear window opening and align the reference marks. (14) Slowly lower the glass to rear window opening fence. Guide the molding into proper position as necessary. Push glass inward until molding is flush to liftgate surface (Fig. 7). (15) Clean excess urethane from exterior with Mopart Super Kleen, or equivalent. (16) Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. (17) Install rear window side moldings and wiper arm (Fig. 6). (18) Install interior trim. (19) After urethane has cured, remove tape strips and water test rear window to verify repair. Fig. 7 LOWER REAR WINDOW INTO POSITION 1 - REAR WINDOW WITH MOLDING 2 - LIFTGATE 23 - 112 WEATHERSTRIP/SEALS RS WEATHERSTRIP/SEALS TABLE OF CONTENTS page FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT DOOR OUTER BELT MOLDING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . FRONT DOOR WEATHERSTRIP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 . . . 112 . . . 113 . . . 113 page INSTALLATION . . . . . . . . . . . . . . . . SLIDING DOOR WEATHERSTRIP REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . FRONT DOOR INNER BELT MOLDING REMOVAL . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 113 . . . . . . . . 114 . . . . . . . . 114 . . . . . . . . 114 . . . . . . . . 114 . . . 113 FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL (1) Remove door frame closeout moldings. (2) Pull weatherstrip from glass run channel at rear of door frame, working from the bottom to the top. (3) Disengage clip attaching weatherstrip to door frame. (4) Pull weatherstrip from lip along top of door frame (Fig. 1). (5) Remove door trim panel. (6) Remove door speaker, if equipped. (7) Remove watershed as necessary to gain access to screw attaching front lower corner of glass run weatherstrip to inner door panel. (8) Remove screw attaching glass run weatherstrip to inner door panel. (9) Remove inner belt weatherstrip. (10) Pull weatherstrip from front glass run channel. (11) Remove glass run weatherstrip from vehicle. INSTALLATION (1) Position glass run weatherstrip on vehicle (Fig. 1). (2) Push weatherstrip into front glass run channel. (3) Install screw attaching glass run weatherstrip to inner door panel. (4) Install inner belt weatherstrip. (5) Install watershed. (6) Push weatherstrip groove onto lip along top of door frame. (7) Engage clip into slot in door frame. (8) Push weatherstrip into channel at rear of door frame, working from the top to bottom. (9) Install door frame closeout moldings. (10) Install door speaker, if equipped. (11) Install door trim panel. WEATHERSTRIP/SEALS RS 23 - 113 FRONT DOOR GLASS RUN WEATHERSTRIP (Continued) Fig. 1 FRONT DOOR WEATHERSTRIP 1 - DOOR GLASS RUN WEATHERSTRIP 2 - FRONT INNER DOOR 3 - DOOR BELT OUTER WEATHERSTRIP FRONT DOOR OUTER BELT MOLDING REMOVAL (1) Remove the side view mirror. (Refer to 23 BODY/EXTERIOR/SIDE VIEW MIRROR REMOVAL) (2) Remove door trim panel. (3) Roll door glass down. (4) Using a hook tool, disengage interlocking lip at the base of the inward edge of the belt molding (Fig. 1). (5) Remove belt molding from door. INSTALLATION (1) Place belt molding in position on door (Fig. 1). (2) Engage interlocking lip at the base of the inward edge of the belt molding on door panel. (3) Install door trim panel. 4 - DOOR MOUNTED WEATHERSTRIP 5 - DOOR OUTER BELT WEATHERSTRIP FRONT DOOR WEATHERSTRIP REMOVAL (1) Open front door. (2) Using fork tool (C-4829), remove push pin fasteners attaching front door weatherstrip to end frames and bottom of door (Fig. 2). (3) Pull weatherstrip from retaining channel around window frame. (4) Remove weatherstrip from vehicle. INSTALLATION (1) Position weatherstrip on door. (2) Install push pin fasteners attaching front door weatherstrip to end frames and bottom of door (Fig. 2). (3) Install weatherstrip into retaining channel around window frame. (4) Close front door. 23 - 114 WEATHERSTRIP/SEALS RS FRONT DOOR WEATHERSTRIP (Continued) INSTALLATION (1) Place splice at the bottom center of door opening, pushing weatherstrip onto pinch flange around door opening. (2) Tighten quarter panel trim panels. (3) Tighten B-pillar trim covers. (4) Install door opening sill plate. (5) Close sliding and check alignment. FRONT DOOR INNER BELT MOLDING REMOVAL (1) Remove door trim panel. (2) Peel upper corner seals away form inner belt molding to clear removal path. (3) Pull inner belt molding upward to disengage retaining channel in bottom of molding from door panel flange (Fig. 1). (4) Remove inner belt molding from vehicle. Fig. 2 Front Door Weatherstrip 1 2 3 4 - RETAINING CHANNEL PUSH-IN FASTENER WEATHERSTRIP FRONT DOOR SLIDING DOOR WEATHERSTRIP REMOVAL (1) Open sliding door. (2) Remove door opening sill plate. (3) Loosen B-pillar trim covers. (4) Loosen quarter panel trim panels. (5) From splice at the bottom center of door opening, pull weatherstrip from pinch flange around door opening. INSTALLATION (1) Place inner belt molding in position on door (Fig. 1). (2) Push inner belt molding downward to engage retaining channel onto door panel flange. (3) Install upper corner seals in proper location. (4) Install door trim panel. BODY STRUCTURE RS 23 - 115 BODY STRUCTURE TABLE OF CONTENTS page page GAP AND FLUSH SPECIFICATIONS GAP AND FLUSH MEASUREMENTS . . . . . . 115 OPENING DIMENSIONS SPECIFICATIONS BODY OPENING DIMENSIONS . . . . . . . . . . 118 SEALER LOCATIONS SPECIFICATIONS BODY SEALING LOCATIONS . . . . . . . . . . . 121 STUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS . . . . 147 WELD LOCATIONS SPECIFICATIONS WELD LOCATIONS . . . . . . . . . . . . . . . . . . . 156 GAP AND FLUSH SPECIFICATIONS GAP AND FLUSH MEASUREMENTS INDEX DESCRIPTION FIGURE GAP & FLUSH MEASUREMENTS 1 23 - 116 BODY STRUCTURE RS GAP AND FLUSH (Continued) Fig. 1 GAP & FLUSH MEASUREMENTS BODY STRUCTURE RS 23 - 117 GAP AND FLUSH (Continued) SPECIFICATIONS ITEM GAP FLUSH A HOOD TO FASCIA LOCATION (VOYAGER ONLY) 8.0 ± 2.0 PARALLEL WITHIN 2.0 RIGHT TO LEFT 2.5 OVER FLUSH TO HOOD ± 1.5 CONSISTENT WITHIN 2.0 B HEADLAMP MODULE TO HOOD 8.0 ± 2.0 PARALLEL WITHIN 2.0 RIGHT TO LEFT C HOOD TO FENDER (FOR & AFT) D HOOD TO FENDER 4.0 ± 1.5 PARALLEL WITHIN 2.5 ± 1.5 LEFT TO RIGHT UNDER FLUSH ± 2.0 E FENDER TO DOOR 5.0 ± 1.5 PARALLEL WITHIN 2.0 UNDER FLUSH 0.5 ± 1.5 CONSISTENT WITHIN 2.0 F FRONT DOOR TO 9A9 PILLAR COVER G 9A9 PILLAR COVER TO SLIDING DOOR H 0.0 ± 1.5 LEFT TO RIGHT WITHIN 1.5 UNDER FLUSH 0.5 ± 2.0 5.0 ± PARALLEL WITHIN 1.0 1.0 UNDER FLUSH ± CONSISTENT WITHIN 3.0 FRONT DOOR APPLIQUE TO SLIDING DOOR GLASS 5.0 ± 2.0 PARALLEL WITHIN 2.0 1.0 UNDER FLUSH ± 2.0 CONSISTENT WITHIN 3.0 I FRONT DOOR TO SLIDING DOOR 5.0 ± 2.0 PARALLEL WITHIN 2.0 ± 2.0 CONSISTENT WITHIN 2.0 J SLIDING DOOR TO REAR APERTURE GLASS 5.0 ± 2.0 PARALLEL WITHIN 1.5 ± 3.0 CONSISTENT WITHIN 3.0 K SLIDING DOOR TO REAR APERTURE 5.0 ± 1.5 PARALLEL WITHIN 2.0 ± 1.5 CONSISTENT WITHIN 1.5 L TAIL LAMP TO BODY SIDE APERTURE 1.0 ± 1.0 PARALLEL WITHIN 1.5 OVER FLUSH M TAIL LAMP TO LIFTGATE 4.0 ± 2.0 OVER FLUSH N LIFTGATE TO BODY SIDE APERTURE 4.0 ± 1.5 UNDER FLUSH 1.0 ± 2.5 CONSISTENT WITHIN 2.0 O LIFTGATE TO ROOF 8.0 ± 2.0 ± 1.5 P LIFTGATE TO FASCIA Q LIFTGATE TO REAR FASCIA UNDER FLUSH TO 1.0 MAXIMUM OVER FLUSH R FUEL FILLER DOOR TO BODY SIDE APERTURE UNDER FLUSH 0.5 ± 1.0 NOTE: All measurements are in mm. 8.0 ± 2.5 PARALLEL WITHIN 3.0 23 - 118 BODY STRUCTURE RS OPENING DIMENSIONS SPECIFICATIONS BODY OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING 2 LIFTGATE OPENING 3 BODY SIDE OPENINGS 4 Fig. 2 WINDSHIELD OPENING BODY STRUCTURE RS OPENING DIMENSIONS (Continued) Fig. 3 LIFTGATE OPENING 23 - 119 23 - 120 BODY STRUCTURE RS Fig. 4 BODY SIDE OPENINGS OPENING DIMENSIONS (Continued) BODY STRUCTURE RS 23 - 121 SEALER LOCATIONS SPECIFICATIONS BODY SEALING LOCATIONS INDEX DESCRIPTION FIGURE METHODS OF APPLYING AUTO BODY SEALANT 5 LOWER WINDSHIELD OPENING - RIGHT AND LEFT SIDES 6 COWL SIDE - LEFT AND RIGHT SIDES 7 SIDE QUARTER WINDSHIELD OPENING - LEFT AND RIGHT SIDES 8 UPPER WINDSHIELD A-PILLAR - LEFT AND RIGHT SIDES 9 ROOF TRACK C-PILLAR - LEFT AND RIGHT SIDES 10 SLIDING DOOR UPPER FLANGE SEAMS - LEFT AND RIGHT SIDES 11 QUARTER PANEL EXTERIOR AREA - LEFT AND RIGHT SIDES 12 LOWER REAR EXTERIOR CORNER PANELS - LEFT AND RIGHT SIDES 13 LOWER SILL LIFT GATE OPENING - LEFT AND RIGHT SIDES 14 C-PILLAR CAN - LEFT AND RIGHT SIDES 15 SHOCK TOWER AREA - LEFT AND RIGHT SIDES 16 OUTER SHOCK TOWER AREA - LEFT AND RIGHT SIDES 17 CROSS MEMBER SUPPORT - LEFT AND RIGHT SIDES 18 A & B PILLAR FLOOR PAN RISERS - LEFT AND RIGHT SIDES 19 REAR WHEEL HOUSE FLOOR PAN - LEFT AND RIGHT SIDES 20 REAR WHEELHOUSE TO FLOOR PAN - LEFT AND RIGHT SIDES 21 UPPER SLIDING DOOR FLANGE - LEFT AND RIGHT SIDES 22 UPPER LIFTGATE HINGE AREA - LEFT AND RIGHT SIDES 23 REAR BRACKET SUPPORT REAR HANGER - LEFT AND RIGHT SIDES 24 LIFTGATE PANEL OPENING - UNDERSIDE 25 D-PILLAR INSIDE SEAM - LEFT AND RIGHT SIDES 26 REAR TAIL LAMP AREA SEAMS - LEFT AND RIGHT SIDES 27 UPPER LIFTGATE PANEL SILL - LEFT AND RIGHT SIDES 28 FRONT WHEELHOUSE & SHOCK TOWER - LEFT AND RIGHT SIDES 29 REAR QUARTER WHEELHOUSE LIP & SEAT ANCHOR BOLT - LEFT AND RIGHT SIDES 30 TAILLAMP CAN - LEFT AND RIGHT SIDES 31 B-PILLAR AND SILL AREAS - LEFT AND RIGHT SIDES 32 FRONT FLOOR PAN & RISER 33 FLOOR PAN SEAMS - LEFT AND RIGHT SIDES 34 FLOOR PAN & REAR WHEELHOUSE AREA - LEFT AND RIGHT SIDES 35 FLOOR PAN SILL & D-PILLAR SEAMS - LEFT AND RIGHT SIDES 36 LEFT SIDE SEAT ANCHOR REINFORCEMENT - SHORT WHEEL BASE ONLY 37 UNDERBODY - LEFT AND RIGHT SIDES 38 23 - 122 BODY STRUCTURE RS SEALER LOCATIONS (Continued) DESCRIPTION FIGURE ROOF TOP JOINT & UPPER FRONT SLIDING DOOR - LEFT AND RIGHT SIDES 39 ROOF TOP JOINT & UPPER REAR SLIDING DOOR - LEFT AND RIGHT SIDES 40 ROOF TOP JOINT & WINDSHIELD OPENING - LEFT AND RIGHT SIDES 41 LIFT GATE ROOF COACH JOINT - LEFT AND RIGHT SIDES 42 ROOF RAP JOINT - LEFT AND RIGHT SIDES 43 DRAIN HOLE PATCHES 44 WHEELHOUSE VENT HOLE - LEFT SIDE SHOWN - RIGHT SIDE TYPICAL 45 FLOOR PAN HOLES - LEFT AND RIDE SIDES 46 HOOD FRONT HEM FLANGE & SIDES 47 FRONT DOOR LOWER FLANGE 48 LIFTGATE HEM FLANGE AND LATCH COVER SEAMS 49 FRONT DOOR BELT DOOR BELT SEAMS (FRONT) 50 FRONT DOOR BELT DOOR BELT SEAMS (REAR) 51 BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 5 METHODS OF APPLYING AUTO BODY SEALANT 23 - 123 23 - 124 BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 6 LOWER WINDSHIELD OPENING - RIGHT AND LEFT SIDES Fig. 7 COWL SIDE - LEFT AND RIGHT SIDES BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 8 SIDE QUARTER WINDSHIELD OPENING - LEFT AND RIGHT SIDES Fig. 9 UPPER WINDSHIELD A-PILLAR - LEFT AND RIGHT SIDES 23 - 125 23 - 126 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 10 ROOF TRACK C-PILLAR - LEFT AND RIGHT SIDES Fig. 11 SLIDING DOOR UPPER FLANGE SEAMS - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 12 QUARTER PANEL EXTERIOR AREA - LEFT AND RIGHT SIDES Fig. 13 LOWER REAR EXTERIOR CORNER PANELS - LEFT AND RIGHT SIDES 23 - 127 23 - 128 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 14 LOWER SILL LIFTGATE OPENING - LEFT AND RIGHT SIDES Fig. 15 C-PILLAR CAN - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 16 SHOCK TOWER AREA - LEFT AND RIGHT SIDES Fig. 17 OUTER SHOCK TOWER AREA - LEFT AND RIGHT SIDES 23 - 129 23 - 130 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 18 CROSS MEMBER SUPPORT - LEFT AND RIGHT SIDES Fig. 19 A & B PILLAR FLOOR PAN RISERS - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 20 REAR WHEEL HOUSE FLOOR PAN - LEFT AND RIGHT SIDES Fig. 21 REAR WHEELHOUSE TO FLOOR PAN - LEFT AND RIGHT SIDES 23 - 131 23 - 132 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 22 UPPER SLIDING DOOR FLANGE - LEFT AND RIGHT SIDES Fig. 23 UPPER LIFTGATE HINGE AREA - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 24 REAR BRACKET SUPPORT REAR HANGER - LEFT AND RIGHT SIDES Fig. 25 LIFTGATE PANEL OPENING - UNDERSIDE 23 - 133 23 - 134 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 26 D-PILLAR INSIDE SEAM - LEFT AND RIGHT SIDES Fig. 27 REAR TAIL LAMP AREA SEAMS - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 28 UPPER LIFTGATE PANEL SILL - LEFT AND RIGHT SIDES Fig. 29 FRONT WHEELHOUSE & SHOCK TOWER - LEFT AND RIGHT SIDES 23 - 135 23 - 136 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 30 REAR QUARTER WHEELHOUSE LIP & SEAT ANCHOR BOLT - LEFT AND RIGHT SIDES Fig. 31 TAILLAMP CAN - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 32 B-PILLAR AND SILL AREAS - LEFT AND RIGHT SIDES Fig. 33 FRONT FLOOR PAN & RISER 23 - 137 23 - 138 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 34 FLOOR PAN SEAMS - LEFT AND RIGHT SIDES Fig. 35 FLOOR PAN & REAR WHEELHOUSE AREA - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 36 FLOOR PAN SILL & D-PILLAR SEAMS - LEFT AND RIGHT SIDES Fig. 37 LEFT SIDE SEAT ANCHOR REINFORCEMENT - SHORT WHEEL BASE ONLY 23 - 139 23 - 140 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 38 UNDERBODY - LEFT AND RIGHT SIDES Fig. 39 ROOF TOP JOINT & UPPER FRONT SLIDING DOOR - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 40 ROOF TOP JOINT & UPPER REAR SLIDING DOOR - LEFT AND RIGHT SIDES Fig. 41 ROOF TOP JOINT & WINDSHIELD OPENING - LEFT AND RIGHT SIDES 23 - 141 23 - 142 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 42 LIFT GATE ROOF COACH JOINT - LEFT AND RIGHT SIDES Fig. 43 ROOF RAP JOINT - LEFT AND RIGHT SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 44 DRAIN HOLE PATCHES Fig. 45 WHEELHOUSE VENT HOLE - LEFT SIDE SHOWN - RIGHT SIDE TYPICAL 23 - 143 23 - 144 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 46 FLOOR PAN HOLES - LEFT AND RIDE SIDES Fig. 47 HOOD FRONT HEM FLANGE & SIDES RS BODY STRUCTURE RS SEALER LOCATIONS (Continued) Fig. 48 FRONT DOOR LOWER FLANGE Fig. 49 LIFTGATE HEM FLANGE AND LATCH COVER SEAMS 23 - 145 23 - 146 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 50 FRONT DOOR BELT DOOR BELT SEAMS (FRONT) Fig. 51 FRONT DOOR BELT DOOR BELT SEAMS (REAR) RS BODY STRUCTURE RS 23 - 147 STUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS INDEX DESCRIPTION FIGURE UPPER COWL PLENUM, UPPER AND LOWER DASH PANEL 52 ROOF AND REAR QUARTER PANELS - LONG WHEEL BASE ONLY 53 FLOOR PAN - LONG WHEEL BASE ONLY 54 SUSPENSION HANGER REINFORCEMENTS - LONG WHEEL BASE ONLY 55 FRONT HINGE PILLAR REINFORCEMENTS - LONG WHEEL BASE ONLY 56 ROOF AND REAR QUARTER PANELS - SHORT WHEEL BASE ONLY 57 FLOOR PAN - SHORT WHEEL BASE ONLY 58 FRONT SIDE RAILS/OUTER CROSS MEMBER BRACKETS 59 OUTER ROOF PANEL/UPPER WINDSHIELD FRAME 60 COWL SIDE PANEL/ BODY SIDE APERTURE, B-PILLAR/SLIDING DOOR TRACK SUPPORT 61 23 - 148 BODY STRUCTURE STUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 52 UPPER COWL PLENUM, UPPER AND LOWER DASH PANEL RS BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 53 ROOF AND REAR QUARTER PANELS - LONG WHEEL BASE ONLY 23 - 149 23 - 150 BODY STRUCTURE STUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 54 FLOOR PAN - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 55 SUSPENSION HANGER REINFORCEMENTS - LONG WHEEL BASE ONLY Fig. 56 FRONT HINGE PILLAR REINFORCEMENTS - LONG WHEEL BASE ONLY 23 - 151 23 - 152 BODY STRUCTURE STUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 57 ROOF AND REAR QUARTER PANELS - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 58 FLOOR PAN - SHORT WHEEL BASE ONLY 23 - 153 23 - 154 BODY STRUCTURE STUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 59 FRONT SIDE RAILS/OUTER CROSS MEMBER BRACKETS Fig. 60 OUTER ROOF PANEL/UPPER WINDSHIELD FRAME RS BODY STRUCTURE RS 23 - 155 STUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 61 COWL SIDE PANEL/ BODY SIDE APERTURE, B-PILLAR/SLIDING DOOR TRACK SUPPORT 23 - 156 BODY STRUCTURE RS WELD LOCATIONS SPECIFICATIONS WELD LOCATIONS INDEX DESCRIPTION FIGURE FRONT FENDER SHIELD - RIGHT 62 FRONT FENDER SHIELD - LEFT 63 STRUT TOWER AND REINFORCEMENTS - RIGHT 64 SUSPENSION RETAINERS AND REINFORCEMENTS - RIGHT 65 STRUT TOWER AND REINFORCEMENTS - LEFT 66 SUSPENSION RETAINERS AND REINFORCEMENTS - LEFT 67 FLOOR PAN REINFORCEMENTS - SIDE RAILS 68 REAR SUSPENSION BRACKETS 69 FLOOR PAN CROSS MEMBERS 70 SEAT REINFORCEMENTS - LONG WHEEL BASE ONLY 71 STRIKER REINFORCEMENTS - LONG WHEEL BASE ONLY 72 FUEL TANK MOUNTING/REAR SEAT AND SUSPENSION 73 REAR SUSPENSION HANGER BRACKETS - LONG WHEEL BASE 74 FRONT SEAT CROSS MEMBER 75 FLOOR PAN SIDE RAIL REINFORCEMENT 76 SILL BULKHEAD REINFORCEMENTS 77 FLOOR PAN CROSS MEMBER REINFORCEMENTS 78 FRONT SEAT CROSS MEMBER 79 SEAT REINFORCEMENT CROSS MEMBERS - SHORT WHEEL BASE 80 CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE 81 REAR SUSPENSION HANGER BRACKETS - SHORT WHEEL BASE 82 LOWER LIFTGATE PANEL LATCH REINFORCEMENT 83 ENGINE MOUNTING PLATE AND TOW BRACKET 84 HEADLAMP MOUNTING PLATE 85 LOWER RADIATOR CROSS MEMBER BRACKETS 86 CROSS MEMBER EXTENSIONS 87 JACK MOUNTING BRACKET - LONG WHEEL BASE SHOWN, SHORT SIMILAR 88 FRONT SEAT CROSS MEMBER - LONG WHEELBASE ONLY 89 FRONT SEAT CROSS MEMBER - ALL WHEEL DRIVE ONLY 90 FUEL TANK SUPPORT CROSS MEMBERS - LONG WHEEL BASE ONLY 91 REAR SUPPORT AND TIRE STOWAGE CROSS MEMBERS - LONG WHEEL BASE ONLY 92 INNER SIDE SILLS - LONG WHEEL BASE ONLY 93 WHEELHOUSES, SIDE SILLS, SUSPENSION BRACKETS - LONG WHEEL BASE ONLY 94 REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 95 BODY STRUCTURE RS 23 - 157 WELD LOCATIONS (Continued) DESCRIPTION FIGURE FUEL TANK SUPPORT AND TIRE STOWAGE - SHORT WHEEL BASE ONLY 96 INNER SIDE SILLS - SHORT WHEEL BASE ONLY 97 REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 98 CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE ONLY 99 WHEELHOUSES - SHORT WHEEL BASE ONLY 100 FRONT SEAT CROSS MEMBER - SHORT WHEELBASE, ALL WHEEL DRIVE ONLY 101 FLOOR PAN SIDE RAIL - LONG WHEEL BASE ONLY 102 INNER BODY SIDE SILL REINFORCEMENTS 103 TOE BOARD CROSS MEMBER 104 FRONT SIDE RAIL - SHORT WHEEL BASE ONLY 105 DASH PANEL REINFORCEMENT 106 LOWER COWL PLENUM 107 UPPER COWL PLENUM SUPPORT 108 UPPER DASH PANEL 109 COWL SIDE PANELS 110 INSTRUMENT PANEL ATTACHMENT TAPPING PLATES 111 INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL 112 STRUT TOWER BRACKET AND COWL PLENUM 113 FRONT SIDE RAILS TO LOWER DASH PANEL 114 INNER BODY SIDE SILL TO LOWER DASH PANEL 115 FRONT HINGE TAPPING PLATE 116 FRONT HINGE PILLAR 117 INNER WINDSHIELD FRAME 118 WINDSHIELD FRAME 119 FENDER BRACKET 120 INNER B-PILLAR 121 STRIKER LATCH AND TAPPING PLATES 122 RIGHT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 123 RIGHT REAR INNER QUARTER PANEL/OUTER WHEELHOUSE - LONG WHEEL BASE ONLY 124 RIGHT REAR BODY SIDE APERTURE - LONG WHEEL BASE ONLY 125 STRIKER LATCH REINFORCEMENT - LONG WHEEL BASE ONLY 126 BELT TAPPING PLATE - LONG WHEEL BASE ONLY 127 C-PILLAR REINFORCEMENT - LONG WHEEL BASE ONLY 128 OUTER WHEELHOUSE - LONG WHEEL BASE ONLY 129 C AND D-PILLAR INNER REINFORCEMENTS - LONG WHEEL BASE ONLY 130 LEFT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 131 OUTER WHEELHOUSE EXTENSION - LONG WHEEL BASE ONLY 132 TAIL LAMP - LONG WHEEL BASE ONLY 133 SLIDING DOOR LATCH - LONG WHEEL BASE ONLY 134 ROOF BOW EXTENSION - LONG WHEEL BASE ONLY 135 RIGHT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 136 23 - 158 BODY STRUCTURE RS WELD LOCATIONS (Continued) DESCRIPTION FIGURE LATCH REINFORCEMENT AND OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 137 D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY 138 OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 139 LEFT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 140 LATCH REINFORCEMENT - SHORT WHEEL BASE ONLY 141 D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY 142 OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 143 BODY SIDE APERTURE RIGHT SIDE- LONG WHEEL BASE ONLY 144 BODY SIDE APERTURE LEFT SIDE - LONG WHEEL BASE ONLY 145 BODY SIDE APERTURE RIGHT SIDE - SHORT WHEEL BASE ONLY 146 BODY SIDE APERTURE LEFT SIDE - SHORT WHEEL BASE ONLY 147 LOWER SLIDING DOOR TRACK 148 LIFTGATE UPPER FRAME 149 UPPER WINDSHIELD FRAME 150 FRONT FENDER SHIELD BEAM 151 FRONT FENDER SHIELD BEAM/COWL SIDE PANEL 152 HINGE PILLAR REINFORCEMENT 153 INNER SIDE SILL - LONG WHEEL BASE ONLY 154 INNER SIDE SILL/OUTER SIDE SILL - LONG WHEEL BASE ONLY 155 LOWER SLIDING DOOR TRACK REINFORCEMENT - LONG WHEEL BASE ONLY 156 UPPER WINDSHIELD FRAME/ROOF PANEL - LONG WHEEL BASE ONLY 157 ROOF BOWS/INNER ROOF SIDE RAILS 158 OUTER ROOF PANEL - LONG WHEEL BASE ONLY 159 INNER SIDE SILL - SHORT WHEEL BASE ONLY 160 INNER/OUTER SIDE SILLS - SHORT WHEEL BASE ONLY 161 LOWER SLIDING DOOR TRACK - SHORT WHEEL BASE ONLY 162 UPPER WINDSHIELD FRAME/OUTER ROOF PANEL - SHORT WHEEL BASE ONLY 163 REAR SUSPENSION HANGERS - LONG WHEEL BASE SHOWN, SHORT WHEEL BASE TYPICAL 164 FRONT LOWER LIFTGATE OPENING 165 REAR JACKING REINFORCEMENT - LONG WHEEL BASE ONLY 166 INNER WHEELHOUSE - LONG WHEEL BASE ONLY 167 SUSPENSION HANGER REINFORCEMENT - LONG WHEEL BASE ONLY 168 LOWER LIFTGATE OPENING PANEL - LONG WHEEL BASE ONLY 169 ROOF BOWS/UPPER LIFTGATE FRAME - LONG WHEEL BASE ONLY 170 BODY SIDE APERTURE/INNER QUARTER PANEL - LONG WHEEL BASE ONLY 171 REAR JACKING REINFORCEMENT - SHORT WHEEL BASE ONLY 172 INNER WHEELHOUSE/INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 173 SUSPENSION HANGER REINFORCEMENT - SHORT WHEEL BASE ONLY 174 LOWER LIFTGATE OPENING - SHORT WHEEL BASE ONLY 175 ROOF PANEL/ROOF RAIL - SHORT WHEEL BASE ONLY 176 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 62 FRONT FENDER SHIELD - RIGHT Fig. 63 FRONT FENDER SHIELD - LEFT 23 - 159 23 - 160 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 64 STRUT TOWER AND REINFORCEMENTS - RIGHT RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 65 SUSPENSION RETAINERS AND REINFORCEMENTS - RIGHT 23 - 161 23 - 162 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 66 STRUT TOWER AND REINFORCEMENTS - LEFT RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 67 SUSPENSION RETAINERS AND REINFORCEMENTS - LEFT 23 - 163 23 - 164 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 68 FLOOR PAN REINFORCEMENTS - SIDE RAILS RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 69 REAR SUSPENSION BRACKETS 23 - 165 23 - 166 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 70 FLOOR PAN CROSS MEMBERS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 71 SEAT REINFORCEMENTS - LONG WHEEL BASE ONLY 23 - 167 23 - 168 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 72 STRIKER REINFORCEMENTS - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 73 FUEL TANK MOUNTING/REAR SEAT AND SUSPENSION 23 - 169 23 - 170 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 74 REAR SUSPENSION HANGER BRACKETS - LONG WHEEL BASE RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 75 FRONT SEAT CROSS MEMBER 23 - 171 23 - 172 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 76 FLOOR PAN SIDE RAIL REINFORCEMENT RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 77 SILL BULKHEAD REINFORCEMENTS 23 - 173 23 - 174 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 78 FLOOR PAN CROSS MEMBER REINFORCEMENTS RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 79 FRONT SEAT CROSS MEMBER 23 - 175 23 - 176 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 80 SEAT REINFORCEMENT CROSS MEMBERS - SHORT WHEEL BASE RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 81 CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE 23 - 177 23 - 178 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 82 REAR SUSPENSION HANGER BRACKETS - SHORT WHEEL BASE RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 83 LOWER LIFTGATE PANEL LATCH REINFORCEMENT 23 - 179 23 - 180 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 84 ENGINE MOUNTING PLATE AND TOW BRACKET RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 85 HEADLAMP MOUNTING PLATE 23 - 181 23 - 182 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 86 LOWER RADIATOR CROSS MEMBER BRACKETS RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 87 CROSS MEMBER EXTENSIONS 23 - 183 23 - 184 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 88 JACK MOUNTING BRACKET - LONG WHEEL BASE SHOWN, SHORT SIMILAR RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 89 FRONT SEAT CROSS MEMBER - LONG WHEELBASE ONLY Fig. 90 FRONT SEAT CROSS MEMBER - ALL WHEEL DRIVE ONLY 23 - 185 23 - 186 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 91 FUEL TANK SUPPORT CROSS MEMBERS - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS 23 - 187 WELD LOCATIONS (Continued) Fig. 92 REAR SUPPORT AND TIRE STOWAGE CROSS MEMBERS - LONG WHEEL BASE ONLY 23 - 188 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 93 INNER SIDE SILLS - LONG WHEEL BASE ONLY Fig. 94 WHEELHOUSES, SIDE SILLS, SUSPENSION BRACKETS - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 95 REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 23 - 189 23 - 190 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 96 FUEL TANK SUPPORT AND TIRE STOWAGE - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 97 INNER SIDE SILLS - SHORT WHEEL BASE ONLY 23 - 191 23 - 192 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 98 REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 99 CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE ONLY 23 - 193 23 - 194 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 100 WHEELHOUSES - SHORT WHEEL BASE ONLY Fig. 101 FRONT SEAT CROSS MEMBER - SHORT WHEELBASE, ALL WHEEL DRIVE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 102 FLOOR PAN SIDE RAIL - LONG WHEEL BASE ONLY 23 - 195 23 - 196 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 103 INNER BODY SIDE SILL REINFORCEMENTS Fig. 104 TOE BOARD CROSS MEMBER BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 105 FRONT SIDE RAIL - SHORT WHEEL BASE ONLY 23 - 197 23 - 198 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 106 DASH PANEL REINFORCEMENT BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 107 LOWER COWL PLENUM 23 - 199 23 - 200 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 108 UPPER COWL PLENUM SUPPORT BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 109 UPPER DASH PANEL 23 - 201 23 - 202 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 110 COWL SIDE PANELS Fig. 111 INSTRUMENT PANEL ATTACHMENT TAPPING PLATES BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 112 INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL Fig. 113 STRUT TOWER BRACKET AND COWL PLENUM 23 - 203 23 - 204 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 114 FRONT SIDE RAILS TO LOWER DASH PANEL RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 115 INNER BODY SIDE SILL TO LOWER DASH PANEL 23 - 205 23 - 206 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 116 FRONT HINGE TAPPING PLATE BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 117 FRONT HINGE PILLAR 23 - 207 23 - 208 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 118 INNER WINDSHIELD FRAME BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 119 WINDSHIELD FRAME 23 - 209 23 - 210 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 120 FENDER BRACKET BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 121 INNER B-PILLAR 23 - 211 23 - 212 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 122 STRIKER LATCH AND TAPPING PLATES Fig. 123 RIGHT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS 23 - 213 WELD LOCATIONS (Continued) Fig. 124 RIGHT REAR INNER QUARTER PANEL/OUTER WHEELHOUSE - LONG WHEEL BASE ONLY Fig. 125 RIGHT REAR BODY SIDE APERTURE - LONG WHEEL BASE ONLY 23 - 214 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 126 STRIKER LATCH REINFORCEMENT - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 127 BELT TAPPING PLATE - LONG WHEEL BASE ONLY 23 - 215 23 - 216 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 128 C-PILLAR REINFORCEMENT - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 129 OUTER WHEELHOUSE - LONG WHEEL BASE ONLY Fig. 130 C AND D-PILLAR INNER REINFORCEMENTS - LONG WHEEL BASE ONLY 23 - 217 23 - 218 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 131 LEFT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 132 OUTER WHEELHOUSE EXTENSION - LONG WHEEL BASE ONLY 23 - 219 23 - 220 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 133 TAIL LAMP - LONG WHEEL BASE ONLY Fig. 134 SLIDING DOOR LATCH - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 135 ROOF BOW EXTENSION - LONG WHEEL BASE ONLY 23 - 221 23 - 222 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 136 RIGHT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS 23 - 223 WELD LOCATIONS (Continued) Fig. 137 LATCH REINFORCEMENT AND OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 23 - 224 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 138 D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 139 OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 23 - 225 23 - 226 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 140 LEFT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 141 LATCH REINFORCEMENT - SHORT WHEEL BASE ONLY 23 - 227 23 - 228 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 142 D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 143 OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 23 - 229 23 - 230 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 144 BODY SIDE APERTURE RIGHT SIDE- LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 145 BODY SIDE APERTURE LEFT SIDE - LONG WHEEL BASE ONLY 23 - 231 23 - 232 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 146 BODY SIDE APERTURE RIGHT SIDE - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 147 BODY SIDE APERTURE LEFT SIDE - SHORT WHEEL BASE ONLY 23 - 233 23 - 234 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 148 LOWER SLIDING DOOR TRACK BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 149 LIFTGATE UPPER FRAME Fig. 150 UPPER WINDSHIELD FRAME 23 - 235 23 - 236 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 151 FRONT FENDER SHIELD BEAM BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 152 FRONT FENDER SHIELD BEAM/COWL SIDE PANEL 23 - 237 23 - 238 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 153 HINGE PILLAR REINFORCEMENT BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 154 INNER SIDE SILL - LONG WHEEL BASE ONLY 23 - 239 23 - 240 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 155 INNER SIDE SILL/OUTER SIDE SILL - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 156 LOWER SLIDING DOOR TRACK REINFORCEMENT - LONG WHEEL BASE ONLY 23 - 241 23 - 242 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 157 UPPER WINDSHIELD FRAME/ROOF PANEL - LONG WHEEL BASE ONLY Fig. 158 ROOF BOWS/INNER ROOF SIDE RAILS RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 159 OUTER ROOF PANEL - LONG WHEEL BASE ONLY 23 - 243 23 - 244 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 160 INNER SIDE SILL - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 161 INNER SIDE/OUTER SIDE SILLS - SHORT WHEEL BASE ONLY 23 - 245 23 - 246 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 162 LOWER SLIDING DOOR TRACK - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 163 UPPER WINDSHIELD FRAME/OUTER ROOF PANEL - SHORT WHEEL BASE ONLY 23 - 247 23 - 248 BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 164 REAR SUSPENSION HANGERS - LONG WHEEL BASE SHOWN, SHORT WHEEL BASE TYPICAL BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 165 FRONT LOWER LIFTGATE OPENING Fig. 166 REAR JACKING REINFORCEMENT - LONG WHEEL BASE ONLY 23 - 249 23 - 250 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 167 INNER WHEELHOUSE - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 168 SUSPENSION HANGER REINFORCEMENT - LONG WHEEL BASE ONLY 23 - 251 23 - 252 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 169 LOWER LIFTGATE OPENING PANEL - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 170 ROOF BOWS/UPPER LIFTGATE FRAME - LONG WHEEL BASE ONLY 23 - 253 23 - 254 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 171 BODY SIDE APERTURE/INNER QUARTER PANEL - LONG WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 172 REAR JACKING REINFORCEMENT - SHORT WHEEL BASE ONLY 23 - 255 23 - 256 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 173 INNER WHEELHOUSE/INNER QUARTER PANEL - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 174 SUSPENSION HANGER REINFORCEMENT - SHORT WHEEL BASE ONLY 23 - 257 23 - 258 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 175 LOWER LIFTGATE OPENING - SHORT WHEEL BASE ONLY RS BODY STRUCTURE RS WELD LOCATIONS (Continued) Fig. 176 ROOF PANEL/ROOF RAIL - SHORT WHEEL BASE ONLY 23 - 259 LAMPS RS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR . . . . . . . . . . . . . . . 25 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page LAMPS/LIGHTING - EXTERIOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WARNING .............................3 SPECIFICATIONS EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 4 BRAKE LAMP SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH .............................4 REMOVAL .............................5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CENTER HIGH MOUNTED STOP LAMP REMOVAL .............................6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CENTER HIGH MOUNTED STOP LAMP UNIT REMOVAL .............................6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FOG LAMP DIAGNOSIS AND TESTING - FOG LAMP . . . . . . 7 REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FOG LAMP - EXPORT REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FOG LAMP UNIT STANDARD PROCEDURE STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 10 STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT - EXPORT . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 FRONT POSITION LAMP - EXPORT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 page HEADLAMP DIAGNOSIS AND TESTING - HEADLAMP . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . HEADLAMP - EXPORT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . HEADLAMP LEVELING MOTOR - EXPORT DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . HEADLAMP LEVELING SWITCH - EXPORT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - HEADLAMP LEVELING SWITCH - EXPORT . . . . . . . HEADLAMP SWITCH DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - HEADLAMP SWITCH - EXPORT . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . HEADLAMP UNIT STANDARD PROCEDURE STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT - EXPORT . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . LICENSE LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . MULTI-FUNCTION SWITCH DESCRIPTION - TURN SIGNAL SYSTEM . . . . . 12 . . . . 14 . . . . 14 . . . . 14 . . . . 14 . . . . 15 . . . . 15 . . . . 15 . . . . 16 . . . . 16 . . . . 16 . . . . 17 . . . . 17 . . . . 17 . . . . 17 . . . . 19 . . . . 19 . . . . 20 . . . . 21 . . . . 21 . . . . 21 8L - 2 LAMPS/LIGHTING - EXTERIOR OPERATION - TURN SIGNAL SYSTEM DIAGNOSIS AND TESTING - MULTIFUNCTION SWITCH . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . PARK/TURN SIGNAL LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . PARK/TURN SIGNAL LAMP - EXPORT REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . REAR FOG LAMP - EXPORT DESCRIPTION . . . . . . . . . . . . . . . . . RS . . . . . . . 21 . . . . . . . . 22 . . . . . . . . 22 . . . . . . . . 22 . . . . . . . . 22 . . . . . . . . 22 . . . . . . . . 22 . . . . . . . . 23 REPEATER LAMP - EXPORT REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . TAIL LAMP REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . TAIL LAMP - EXPORT REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . TAIL LAMP UNIT REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . . . . 24 . . . . . . . . 23 LAMPS/LIGHTING - EXTERIOR DAYTIME RUNNING LAMPS DESCRIPTION Operating the high-beam headlamps at reduced power provides daytime running lamps, which are required on all new Canadian vehicles. LAMP SYSTEMS Lighting circuits are protected by fuses. Lighting circuits require an overload protected power source, on/off device, lamps and body ground to operate properly. Plastic lamps require a wire in the harness to supply body ground to the lamp socket. Replace sockets and bulbs that are corroded. Some of the interior and exterior lighting functions are governed by the Body Control Module (BCM). The headlamp, dome, and the door ajar switches provide signals to the BCM. The BCM in turn sends a Programmable Communication Interface (PCI) bus message to the Front Control Module (FCM) to enable the necessary drivers to set the required illumination configuration. Wire connectors can make intermittent contact or become corroded. Before coupling wire connectors, inspect the terminals inside the connector. Male terminals should not be bent or disengaged from the insulator. Female terminals should not be sprung open or disengaged from the insulator. Bent and sprung terminals can be repaired using needle nose pliers and pick tool. Corroded terminals appear chalky or green. Corroded terminals should be replaced to avoid recurrence of the problem symptoms. Begin electrical system failure diagnosis by testing related fuses in the fuse block and intelligent power module. Verify that bulbs are in good condition and test continuity of the circuit ground. Refer to the appropriate wiring information. AUTOMATIC HEADLAMP SYSTEM The Automatic Headlamp system turns the instrumentation and exterior illumination lamps ON when the ambient light levels are Night and the engine RPM is 450 or above, and OFF when light levels are Day. HEADLAMPS ON WITH WINDSHIELD WIPERS For vehicles equipped with the Automatic Headlamp System, the instrumentation and exterior illumination lamps will be turned ON when the headlamp switch is in the AUTO position, RPM > 450 and the windshield wipers have been in the intermittent, low or high mode of operation for more than ten seconds. When the windshield wipers are turned OFF the Body Control Module will determine if the instrumentation and exterior illumination lamps should remain ON base upon the current ambient light level. HEADLAMP SYSTEM The configuration of the headlamp system of headlamps, park lamps and fog lamps is determined by the BCM. The BCM determines the lighting configuration as a result of the inputs from the ignition switch, headlamp switch and multi-function switch. A PCI bus is transmitted from the BCM to the FCM to enable the necessary drivers to set the illumination configuration. Four wires are connected between the headlamp switch and the BCM. The first wire contains information regarding the position of the headlamp switch (Off, Automatic Headlamps, Automatic Headlamp switch fog, Park with Fog, Head, or Head with Fog Lamps). The second wire contains information regarding the position of the dimmer switch (Dome Lamp, Daytime Brightness, Dimming Level or Off). The third wire is a dedicated signal return (ground) wire. The fourth wire provides power to the front fog lamp indicator. HEADLAMP TIME DELAY SYSTEM The headlamp time delay system is controlled by the Body Control Module (BCM) via a PCI bus mes- LAMPS/LIGHTING - EXTERIOR RS 8L - 3 LAMPS/LIGHTING - EXTERIOR (Continued) sage transmitted by the BCM to the FCM to turn off the headlamps. OPERATION AUTOMATIC HEADLAMP SYSTEM Automatic headlamps are controlled by the Body Control Module (BCM). With the headlamp switch in the AUTO position, the BCM will control the headlamp, parking, side marker, tail and instrumentation lamps based on ambient light levels. Ambient light levels are monitored by the BCM using the Day/Night signal and Electrochromatic Mirror (ECM) present from the Compass Mini Trip (CMTC) located on the front windshield in front of the rear view mirror ECM. Ambient light readings are averaged to limit cycling the lamps ON and OFF when passing through areas with varying light levels. The automatic headlamps will only function when the engine is running with RPM > 450. When the headlamp switch is in the AUTO position (Automatic mode), the Headlamp Time Delay system will function when the ignition switch is placed in any position other than run/start. DAYTIME RUNNING LAMPS Power is reduced using pulse-width modulation to the high beams, where by the power is switched on and off rapidly instead of remaining on continuously. The duration and interval of the power pulses is programmed into the FCM. HEADLAMP SYSTEM The headlamp system will default to headlamps ON position when ignition switch is ON and when an open or short circuit failure occurs on the headlamp switch input. The system will return to normal operation when the open or short is repaired. A fault will be reported by the BCM when a failure occurs on the dimmer or headlamp switch input. If the exterior lamps are ON and the headlamp switch is in any position other than OFF or AUTO and with the ignition switch OFF (LOCK) after 3 minutes the BCM sends a message via PCI bus to the FCM informing the FCM to turn off the headlamps, park lamps and fog lamps. This feature prevents the vehicle battery from being discharged when the vehicle lights have been left ON. HEADLAMP TIME DELAY SYSTEM The headlamp time delay system is activated by turning the headlamps ON (high or low beam) while the engine is running, turning the ignition switch OFF, and then turning the headlamp switch OFF within 45 seconds. The system will not activate if more than 45 seconds elapse between ignition switch OFF and headlamp switch OFF. The BCM will allow the headlamps to remain ON for 90 seconds (config- urable) before they automatically turn off (If the key is in the ignition during the headlamp time delay mode, then both the headlamps and park lamps (including panel dimming) will be ON). Refer to the Owner’s Manual for more information. If the headlamp switch is in the Auto Headlamp Position, the headlamps are ON due to the night signal from the CMTC and the ignition switch is in any position other than run/start, the BCM shall enter a 90 second (configurable) Auto Headlamps time delay mode. If the key is in the ignition during the headlamp time delay mode, then both the headlamps and park lamps (including panel dimming) will be ON. If the key is not in the ignition, then only the headlamps will be ON. The BCM will allow the headlamps to remain ON for 90 seconds before they automatically turn OFF. Refer to the Owner’s Manual for more information. OPTICAL HORN/HIGH BEAMS When the multi-function switch is pulled to the first detent (optical horn) signal, the headlamps are ON, key-in the ignition the BCM shall send a message via PCI bus to the FCM to turn on the headlamps drivers to illuminate all four filaments (Low and High beams). When the multi-function switch is pulled to the second detent (high beam) signal and the headlamps are ON, the BCM shall send a message via PCI bus to the FCM to turn on the headlamps drivers. The High Beams are illuminated and the Low Beams and Fog Lamps (if ON) are extinguished. If the headlamps were in the high beam configuration when power was removed from the headlamps, the headlamps will be configured as low beam the next time they are activated. WARNING WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT. CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. Do not use bulbs other than those indicated in the Bulb Application table. Damage to lamp and/or Daytime Running Lamp Module can result. Do not use fuses, circuit breakers or relays having greater amperage value than indicated on the fuse panel or in the Owners Manual. CAUTION: Do not use bulbs other than those listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. 8L - 4 LAMPS/LIGHTING - EXTERIOR RS LAMPS/LIGHTING - EXTERIOR (Continued) OPERATION SPECIFICATIONS EXTERIOR LAMPS BULB APPLICATION TABLE LAMP BULB BACK-UP 3057 CHMSL 921 FRONT SIDE MARKER/PARK/ TURN 3157A FOG LAMP 9040 HEADLAMP 9007 LICENSE 168 TAIL, STOP 3057 TURN SIGNAL 3057 BULB APPLICATION TABLE - EXPORT LAMP HEADLAMP FRONT POSITION FRONT TURN SIGNAL BULB H7 W5W PY21W SIDE REPEATER T4W LICENSE PLATE W5W/168 REAR TAIL AND STOP P21/5W REAR TURN SIGNAL PY21W BACK-UP P21W REAR FOG P21W CHMSL W16W/921 BRAKE LAMP SWITCH DESCRIPTION The brake lamp switch is located under the instrument panel, at the brake pedal arm (Fig. 3). It has three internal switches controlling various functions of the vehicle. It’s main function is to control operation of the vehicle’s brake lamps. Other functions include speed control deactivation, brake sense for the antilock brake system and brake sense for the brake transmission shift interlock. CAUTION: 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. When the brake pedal is pressed, the plunger on the outside of the brake lamp switch extends outward. This action opens or closes the contacts of the three switches inside the brake lamp switch. With the brake pedal pressed down (plunger extended), the switch for terminals 1 and 2 is closed completing the circuit. The switch for terminals 3 and 4 is open and so is the switch for terminals 5 and 6. When the brake pedal is released (plunger pushed in), the three switches assume the opposite positions. The switch for terminals 1 and 2 is now open while the other two switches are now closed, completing their circuits. A lever on the back of the switch is used to set the switch into the “adjusted” position. A non-adjusted switch will have the lever set to the diagonal position in relation to the switch housing. The plunger can be moved in and out, but the states of the internal switches will not change. CAUTION: Never move the adjustment lever of the new brake lamp switch without it being properly installed in the vehicle first. Such action will render the switch unusable and the switch must be discarded. Once installed in the vehicle as described in the brake lamp switch installation procedure (Refer to 8 ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - INSTALLATION), the new switch’s adjustment lever is rotated to the adjusted position as indicated (Fig. 4). This action locks the plunger to the internal switches. Once in this position the switch is permanently adjusted (or locked) and cannot be readjusted or released even if the lever is moved back. DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH NOTE: Before proceeding with this diagnostic test, verify the adjustment lever on the back of the switch is in the adjusted position. If the lever is in the non-adjusted (diagonal) position it may have never been adjusted (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING EXTERIOR/BRAKE LAMP SWITCH - OPERATION). For adjustment, (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - INSTALLATION) If the electrical circuit has been tested and the brake lamp switch is suspected of being faulty, it can be tested using the following method. LAMPS/LIGHTING - EXTERIOR RS 8L - 5 BRAKE LAMP SWITCH (Continued) (1) Remove the switch from the vehicle. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - REMOVAL) (2) With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown (Fig. 1). You should achieve the results as listed in the figure. If the switch is found to be operating properly, it may be misadjusted. Do not reinstall the switch, replace it. (Refer to 8 - ELECTRICAL/LAMPS/ LIGHTING - EXTERIOR/BRAKE LAMP SWITCH INSTALLATION) CAUTION: 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 any reason, a new switch must be installed and adjusted. REMOVAL (1) Disconnect and isolate the battery negative cable from its post on the battery. (2) Remove silencer panel below steering column and knee blocker. (3) Remove the brake lamp switch by rotating the switch in a counterclockwise direction approximately 30 degrees and pulling it out of the bracket (Fig. 3). Fig. 1 SWITCH TEST - RELEASED POSITION (3) Gently push the plunger on the brake lamp switch in until it stops. (4) With the switch in this depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown (Fig. 2). You should achieve the results as listed in the figure. Fig. 3 Pedal And Brake Lamp Switch 1 2 3 4 Fig. 2 SWITCH TEST - DEPRESSED POSITION If you do not achieve the results as listed in both figures, the switch is faulty and must be replaced. Refer to Removal And Installation in this section. - SWITCH BRACKET BRAKE LAMP SWITCH WIRING CONNECTOR PEDAL AND BRACKET (4) Release the locking tab and disconnect the wiring connector from the switch. (5) Discard the brake lamp switch. It must not be reused. 8L - 6 LAMPS/LIGHTING - EXTERIOR RS BRAKE LAMP SWITCH (Continued) INSTALLATION CAUTION: Do not reuse the original brake 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. (1) Mount and adjust the NEW brake lamp switch using the following procedure: (a) Connect the wiring connector to the switch and latch the locking tab. (b) Install the switch in its bracket by aligning the index tab on the switch with the slot in the mounting bracket. (c) When the switch is fully seated in its bracket, rotate the switch clockwise approximately 30° to lock the switch into place (Fig. 3). (d) With the brake pedal in the fully released position, move the lever on the back of the brake lamp switch from the angled non-adjusted position to the full vertical position as shown (Fig. 4). This will adjust the brake lamp switch to the vehicle. CENTER HIGH MOUNTED STOP LAMP REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove two retaining screws (Fig. 5). (3) Twist socket counter-clockwise and remove from lamp. (4) Pull bulb from socket (Fig. 6). INSTALLATION (1) (2) (3) (4) Push bulb into socket. Install socket into the lamp unit. Install the retaining screws. Reconnect the battery negative cable. CENTER HIGH MOUNTED STOP LAMP UNIT REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the two retaining screws (Fig. 5). Fig. 5 CHMSL Fig. 4 Adjustment Lever Movement (2) Install silencer panel below steering column knee blocker. (3) Reconnect the battery negative terminal. (4) Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. (5) Road test the vehicle to ensure proper operation of the brakes including ABS and speed control (if equipped). 1 - CHMSL UNIT 2 - LIFTGATE (3) Disconnect the rear window washer hose. (4) Remove bulb socket from lamp unit (Fig. 6). INSTALLATION (1) Install bulb socket to lamp unit. (2) Reconnect the rear window washer hose. LAMPS/LIGHTING - EXTERIOR RS 8L - 7 CENTER HIGH MOUNTED STOP LAMP UNIT (Continued) FOG LAMP DIAGNOSIS AND TESTING - FOG LAMP Fig. 6 CHMSL BULB 1 - CHMSL UNIT 2 - CHMSL BULB (3) Install the retaining screws. (4) Reconnect the battery negative cable. When a vehicle experiences problems with the fog lamp system, verify the condition of the battery connections, fuses, charging system, fog lamp bulbs, wire connectors, relay, high beam switch, and headlamp switch. Refer to the appropriate wiring information. Each vehicle is equipped with various lamp assemblies. A good ground is necessary for proper lighting operation. Grounding is provided by the lamp socket when it comes in contact with the metal body, or through a separate ground wire. When changing lamp bulbs check the socket for corrosion. If corrosion is present, clean it with a wire brush. When it is necessary to remove components to service another, it should not be necessary to apply excessive force or bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured edges are not holding the component in place. FOG LAMP DIAGNOSIS CONDITION FOG LAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF. FOG LAMP BULBS BURN OUT FREQUENTLY POSSIBLE CAUSES CORRECTION 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps and posts. 2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt. 3. Charging system output too low. 3. Test and repair charging system. Refer to Electrical, Charging, 4. Battery has insufficient charge. 4. Test battery state-of-charge. Refer to Electrical, Battery System. 5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical, Battery System. 6. Poor lighting circuit Z349/Z248 ground. 6. Test for voltage drop across Z349/248 ground locations. Refer to Electrical, Wiring Information. 1. Charging system output too high. 1. Test and repair charging system. Refer to Electrical, Charging. 2. Loose or corroded terminals or splices in circuit. 2. Inspect and repair all connectors and splices. Refer to Electrical, Wiring Information. 8L - 8 LAMPS/LIGHTING - EXTERIOR RS FOG LAMP (Continued) CONDITION FOG LAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE FOG LAMPS FLASH RANDOMLY FOG LAMPS DO NOT ILLUMINATE POSSIBLE CAUSES CORRECTION 1. Charging system output too low. 1. Test and repair charging system. Refer to Electrical, Charging. 2. Poor lighting circuit Z349/Z248 ground. 2. Test for voltage drop across Z349/Z248 ground locations. Refer to Electrical, Wiring Information. 3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit. 1. Poor lighting circuit Z349/Z248 ground. 1. Test for voltage drop across Z349/Z248 ground locations. Refer to Electrical, Wiring Information. 2. Variable resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit. 3. Faulty fog lamp switch (part of headlamp switch). 3. Replace headlamp switch. 4. Loose or corroded terminals or splices in circuit. 4. Inspect and repair all connectors and splices. Refer to Electrical, Wiring Information. 5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM. 6. PCI Bus Communication. 6. Verify PCI bus message (fog lamp info) transmitted from BCM and received by FCM. 1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring Information. 2. No Z349/Z248 ground at fog lamps. 2. Repair circuit ground. Refer to Electrical, Wiring Information. 3. Faulty fog lamp switch (part of headlamp switch). 3. Replace headlamp switch. 4. Broken connector terminal or wire splice in fog lamp circuit. 4. Repair connector terminal or wire splice. 5. Faulty or burned out bulb. 5. Replace bulb. 6. Is relay engaging? 6. Verify function of fog lamp relay in IPM. 7. PCI Bus Communication. 7. Verify PCI bus message (fog lamp info) transmitted from BCM and received by FCM. LAMPS/LIGHTING - EXTERIOR RS 8L - 9 FOG LAMP (Continued) REMOVAL FOG LAMP - EXPORT (1) Disconnect and isolate the battery negative cable. (2) From behind the bumper fascia, twist bulb counter-clockwise, and remove bulb. (Fig. 7). (3) Remove the wire connector from the fog lamp bulb. (1) Disconnect and isolate the battery negative cable. (2) Remove access cover from under bumper fascia. (3) Disengage spring clip from fog lamp (Fig. 8). Fig. 7 FOG LAMP Fig. 8 FOG LAMP 1 - FOGLAMP MOUNTING NUT 2 - FOGLAMP INSTALLATION (1) Reconnect wire harness to bulb. (2) Install bulb and twist clockwise. (3) Install battery negative cable. REMOVAL 1 - SPRING CLIP 2 - FOG LAMP (4) Remove bulb from lamp. (5) Disconnect wire harness connector. INSTALLATION (1) (2) (3) (4) (5) Connect wire harness connector. Install bulb to lamp. Engage spring clip to fog lamp. Install access cover under bumper fascia. Connect battery negative cable. 8L - 10 LAMPS/LIGHTING - EXTERIOR RS on the alignment screen, the headlamps should be in the “off” position. The fog lamps are adjusted by a adjustment screw located through the lens on Dodge vehicles, and by a knob on the back of the lamp. FOG LAMP UNIT STANDARD PROCEDURE STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT FOG LAMP UNIT ALIGNMENT Prepare an alignment screen (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - STANDARD PROCEDURE). A properly aligned fog lamp will project a pattern on the alignment screen 100 mm (4 in.) below the fog lamp center line and straight ahead (Fig. 9). To improve visual interpretation of the fog lamp pattern STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT - EXPORT Prepare an alignment screen (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - STANDARD PROCEDURE). A properly aligned fog lamp will project a pattern on the alignment screen 200 mm (8 in.) below the fog lamp center line and straight ahead (Fig. 10). To improve visual interpretation of the fog lamp pattern on the alignment screen, the headlamps should be in the “off” position. Fig. 9 FOG LAMP UNIT ALIGNMENT 1 - HIGH INTENSITY AREA 2 - CENTER OF VEHICLE 3 - HORIZONTAL CENTER OF FOG LAMP 4 - 100MM (4 IN.) 5 - 7.62 METERS (25 FT.) 6 - FRONT OF FOG LAMP LAMPS/LIGHTING - EXTERIOR RS 8L - 11 FOG LAMP UNIT (Continued) The fog lamps are adjusted by a adjustment screw located on the underside of the fog lamp unit. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) From behind the bumper fascia, disconnect the wire harness from the fog lamp bulb (Fig. 7). (3) Remove mounting nuts. INSTALLATION (1) Install mounting nuts. (2) Reconnect the wire harness to the fog lamp bulb. (3) Reconnect the battery negative cable. FRONT POSITION LAMP EXPORT REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the headlamp unit (Fig. 11). (3) Remove the plastic cover from the back of the headlamp unit. (4) Pull front position lamp socket from headlamp unit. (5) Pull bulb straight out of socket. INSTALLATION (1) Push bulb into the bulb socket. (2) Insert bulb socket into headlamp unit. (3) Install cover to the back of the headlamp unit. Fig. 10 FOG LAMP UNIT ALIGNMENT - EXPORT 1 - HIGH INTENSITY AREA 2 - CENTER OF VEHICLE 3 - HORIZONTAL CENTER OF FOG LAMP UNIT 4 - 200 MM 5 - 10 METERS 6 - FRONT OF FOG LAMP UNIT 8L - 12 LAMPS/LIGHTING - EXTERIOR RS FRONT POSITION LAMP - EXPORT (Continued) HEADLAMP DIAGNOSIS AND TESTING - HEADLAMP Fig. 11 FRONT POSITION LAMP 1 2 3 4 - TURN SIGNAL LAMP HIGH BEAM LAMP FRONT POSITION LAMP LOW BEAM LAMP (4) Install the headlamp unit. (5) Connect the battery negative cable. When a vehicle experiences problems with the headlamp system, verify the condition of the battery connections, fuses, charging system, headlamp bulbs, wire connectors, relay, high beam switch, dimmer switch, and headlamp switch. Refer to the appropriate wiring information. Each vehicle is equipped with various lamp assemblies. A good ground is necessary for proper lighting operation. Grounding is provided by the lamp socket when it comes in contact with the metal body, or through a separate ground wire. When changing lamp bulbs check the socket for corrosion. If corrosion is present, clean it with a wire brush. When it is necessary to remove components to service another, it should not be necessary to apply excessive force or bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured edges are not holding the component in place. HEADLAMP DIAGNOSIS CONDITION HEADLAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF. HEADLAMP BULBS BURN OUT FREQUENTLY. POSSIBLE CAUSES CORRECTION 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps and posts. 2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt. 3. Charging system output too low. 3. Test and repair charging system, refer to Electrical, Charging 4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to Electrical, Battery System. 5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery System. 6. Poor lighting circuit Z343/Z344ground. 6. Test for voltage drop across Z343/Z344ground locations, refer to Electrical, Wiring Diagram Information. 1. Integrated Power Module (IPM) not controlling voltage. 1. Test and repair Integrated Power Module. 2. Loose or corroded terminals or splices in circuit. 2. Inspect and repair all connectors and splices. Refer to Electrical, Wiring Information. LAMPS/LIGHTING - EXTERIOR RS 8L - 13 HEADLAMP (Continued) CONDITION POSSIBLE CAUSES HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE. 1. Charging system output too low. 1. Test and repair charging system, refer to Electrical, Wiring Information. 2. Poor lighting circuit Z343/Z344ground. 2. Test for voltage drop across Z343/Z344ground locations, refer to Electrical, Wiring Information. 3. High resistance in headlamp circuit. 3. Test amperage draw of headlamp circuit. 1. Poor lighting circuit Z343/Z344ground. 1. Test for voltage drop across Z343/Z344ground locations, refer to Electrical, Wiring Information. 2. Variable resistance in headlamp circuit. 2. Test amperage draw of headlamp circuit. 3. Loose or corroded terminals or splices in circuit. 3. Inspect and repair all connectors and splices, refer to Electrical, Wiring Information. 4. Faulty headlamp switch. 4. Replace headlamp switch. 1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to Electrical, Wiring Information. 2. No Z343/Z344-ground at headlamps. 2. Repair circuit ground, refer to Electrical, Wiring Information. 3. Broken connector terminal or wire splice in headlamp circuit. 3. Repair connector terminal or wire splice. 4. Faulty or burned out bulb. 4. Replace headlamp bulb(s). 5. Body Control Module malfunction. 5. Refer to appropriate Body Control Module diagnostics. 6. PCI Bus Communication 6. Verify messages being transmitted by BCM and received by FCM. 7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM diagnostics. 1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM logged faults). 2. Diagnostic tool indicates (4.7 5.0V) on headlamp switch input to BCM. 2. Inspect and repair terminals, connectors and open circuits. 3. PCI Bus Communication. 3. Verify messages being transmitted by BCM and received by FCM. HEADLAMPS FLASH RANDOMLY HEADLAMPS DO NOT ILLUMINATE. HEADLAMPS ON WITH IGNITION IN RUN, WITH HEADLAMP SWITCH OFF. CORRECTION 8L - 14 LAMPS/LIGHTING - EXTERIOR RS HEADLAMP (Continued) REMOVAL HEADLAMP - EXPORT (1) Disconnect and isolate the battery negative cable. (2) Remove headlamp unit retaining screws. (3) Remove headlamp unit to expose back of unit. (4) Remove wiring connector from bulb. (5) Rotate headlamp bulb retaining ring counterclockwise. (1) Disconnect and isolate the battery negative cable. (2) Remove the headlamp unit. (3) Remove the cover (high beam lamp) or rubber boot (low beam lamp) to access bulbs (Fig. 13). Fig. 12 HEADLAMP Fig. 13 HEADLAMP UNIT 1 - HEADLAMP 2 - HEADLAMP UNIT (6) Pull headlamp bulb and remove from headlamp unit (Fig. 12). INSTALLATION (1) (2) (3) (4) (5) (6) Install headlamp bulb to the headlamp unit. Install headlamp bulb retaining ring. Connect wiring connector to bulb. Install the headlamp unit. Install headlamp unit retaining screws. Reconnect the battery negative cable. REMOVAL 1 2 3 4 - HIGH BEAM LAMP HEADLAMP LEVELING MOTOR LOW BEAM LAMP TURN LAMP (4) Disconnect the wire harness connector. (5) Disengage spring clip from headlamp. (6) Pull headlamp bulb from back of headlamp unit. INSTALLATION (1) Insert headlamp bulb into headlamp unit. (2) Engage spring clip to headlamp. (3) Connect wire harness connector. (4) Install the cover (high beam lamp) or rubber boot (low beam lamp) to headlamp unit. (5) Install the headlamp unit. (6) Connect the battery negative cable. LAMPS/LIGHTING - EXTERIOR RS 8L - 15 HEADLAMP LEVELING MOTOR - EXPORT DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT HEADLAMP LEVELING MOTOR DIAGNOSIS CONDITION ONE MOTOR DOES NOT OPERATE. BOTH MOTORS DO NOT OPERATE POSSIBLE CAUSES CORRECTION 1. Poor electrical connection at motor 1. Check for proper electrical connection at motor 2. No voltage at motor 2. Repair no voltage condition. Refer to Wiring Diagrams 3. No ground at motor 3. Repair no ground condition. Refer to Wiring Diagrams 4. Defective motor 4. Replace leveling motor 1. No voltage at or from headlamp leveling switch 1. Repair no voltage condition. Check for proper headlamp leveling switch operation 2. No voltage at leveling motors 2. Repair no voltage condition. Refer to Wiring Diagrams 3. No ground at leveling motors 3. Repair no ground condition. Refer to Wiring Diagrams 4. Both motors defective 4. Replace both motors REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove headlamp unit. (3) Disconnect electrical connector from headlamp leveling motor. (4) Remove the two mounting screws. (5) Gently pry motor from headlamp unit (Fig. 14). INSTALLATION (1) (2) (3) (4) (5) Press motor into position. Install the two mounting screws. Connect the electrical connector to motor. Install the headlamp unit. Connect the battery negative cable. Fig. 14 HEADLAMP LEVELING MOTOR - EXPORT 1 - HIGH BEAM HEADLAMP 2 - HEADLAMP LEVELING MOTOR 3 - LOW BEAM HEADLAMP 8L - 16 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING SWITCH - EXPORT DESCRIPTION Some vehicles are equipped with a remote headlamp leveling system. This system allows the driver to adjust the vertical headlamp aim from the interior of the vehicle to compensate for passenger or cargo load. The headlamp leveling switch is located next to the headlamp switch on the instrument panel (Fig. 15). If the headlamp leveling switch is faulty or damaged, the headlamp switch must be replaced. RS HEADLAMP SWITCH DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - HEADLAMP SWITCH Using a Digital Multi-meter, perform the HEADLAMP SWITCH CONTINUITY test and refer to (Fig. 16). If the Headlamp Switch is not within specifications replace the switch. Fig. 16 HEADLAMP SWITCH CONNECTOR Fig. 15 HEADLAMP LEVELING SWITCH 1 2 3 4 - POWER MIRROR SWITCH HEADLAMP SWITCH INTERIOR DIMMER HEADLAMP LEVELING SWITCH HEADLAMP SWITCH CONTINUITY HEADLAMP SWITCH POSITION 13 - WAY CONNECTOR TERMINAL RESISTANCE OFF 11 TO 6 3651 - 3729 V DIAGNOSIS AND TESTING - HEADLAMP LEVELING SWITCH - EXPORT PARKING LAMPS ON 11 TO 6 1697 - 2517 V The headlamp leveling switch is located next to the headlamp switch on the instrument panel. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ HEADLAMP SWITCH - DIAGNOSIS AND TESTING) for diagnosis of the headlamp leveling switch. If the headlamp leveling switch is faulty, the headlamp switch must be replaced. PARKING LAMPS WITH FRONT FOG LAMPS ON 11 TO 6 5765 - 5886 V HEADLAMPS ON 11 TO 6 788 - 809 V AUTO ON 11 TO 6 10056 - 10264 V HEADLAMPS ON WITH FRONT FOG LAMPS 11 TO 6 1171 - 1200 V AUTO ON WITH FRONT FOG LAMPS ON 11 TO 6 24278 - 24773 V LAMPS/LIGHTING - EXTERIOR RS 8L - 17 HEADLAMP SWITCH (Continued) DIMMER POSITION 13 - WAY CONNECTOR TERMINAL RESISTANCE DIMMER POSITION 13 - WAY CONNECTOR TERMINAL RESISTANCE DOME 12 TO 6 15568 - 23357 V DOME 12 TO 6 15568 - 23357 V PARADE 12 TO 6 5168 - 7757 V PARADE 12 TO 6 5168 - 7757 V DIM HIGH 12 TO 6 2288 - 3437 V DIM HIGH 12 TO 6 2288 - 3437 V DIM LOW 12 TO 6 688 - 1037 V DIM LOW 12 TO 6 688 - 1037 V OFF 12 TO 6 240 - 365 V OFF 12 TO 6 240 - 365 V HEADLAMP LEVELING SWITCH POSITION 13 - WAY CONNECTOR TERMINAL RESISTANCE 1 TO 7 3238 - 3456 V 1 TO 2 3181 - 3400 V 1 1 TO 7 1195 - 1225 V 2 1 TO 7 746 - 765 V DIAGNOSIS AND TESTING - HEADLAMP SWITCH - EXPORT Using a Digital Multi-meter, refer to the HEADLAMP SWITCH CONTINUITY table and (Fig. 17). If the Headlamp Switch is not within specifications, replace as necessary. 0 REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the Instrument Panel Lower Steering Column Cover. Refer to Body, Instrument Panel, Lower Steering Column Cover, Removal. (3) Reach up behind the left side of the instrument panel and depress spring clip on top or bottom of headlamp switch. Firmly push out on the headlamp switch assembly. (4) Disconnect the wiring connectors. (5) Remove switch from vehicle. Fig. 17 HEADLAMP SWITCH CONNECTOR HEADLAMP SWITCH CONTINUITY HEADLAMP SWITCH POSITION 13 - WAY CONNECTOR TERMINAL RESISTANCE OFF 11 TO 6 3651 - 3729 V PARKING LAMPS ON 11 TO 6 1697 - 2517 V PARKING LAMPS WITH FRONT FOG LAMPS ON 11 TO 6 5765 - 5886 V HEADLAMPS ON 11 TO 6 788 - 809 V HEADLAMPS ON WITH FRONT FOG LAMPS 11 TO 6 1171 - 1200 V REAR FOG LAMPS 11 TO 6 271 - 277 V FRONT FOG INDICATOR 10 TO 4 LED REAR FOG INDICATOR 5 TO 4 LED ILLUMINATION 8 TO 4 CONTINUITY INSTALLATION (1) Connect the wiring connectors. (2) Place headlamp switch assembly into position and firmly snap into place. (3) Install the Instrument Panel Lower Steering Column Cover. Refer to Body, Instrument Panel, Lower Steering Column Cover, Installation. (4) Connect the battery negative cable. HEADLAMP UNIT STANDARD PROCEDURE STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT HEADLAMP UNIT ALIGNMENT PREPARATION (1) Verify headlamp dimmer switch and high beam indicator operation. (2) Inspect and correct damaged or defective components that could interfere with proper headlamp alignment. 8L - 18 LAMPS/LIGHTING - EXTERIOR RS HEADLAMP UNIT (Continued) (3) Verify proper tire inflation. (4) Clean headlamp lenses. (5) Verify that luggage area is loaded as the vehicle is routinely used. (6) Fuel tank should be FULL. Add 2.94 kg (6.5 lbs.) of weight over the fuel tank for each estimated gallon of missing fuel. ALIGNMENT SCREEN PREPARATION (1) Position vehicle on a level surface perpendicular to a flat wall 7.62 meters (25 ft.) away from front of headlamp lens (Fig. 18). (2) If necessary, tape a line on the floor 7.62 meters (25 ft.) away from and parallel to the wall. (3) Rock vehicle side-to-side three times and allow suspension to stabilize. (4) Jounce front suspension three times by pushing downward on front bumper and releasing. (5) Measure the distance from the center of headlamp lens to the floor. Transfer measurement to the alignment screen (with tape). Use this line for up/down adjustment reference. Fig. 18 HEADLAMP ALIGNMENT SCREEN 1 - CENTER OF HEADLAMPS 2 - HEADLAMP BEAM 3 - FRONT OF HEADLAMP 4 - 7.62 METERS (25 FT.) LAMPS/LIGHTING - EXTERIOR RS 8L - 19 HEADLAMP UNIT (Continued) HEADLAMP ADJUSTMENT The low beam headlamp will project on the screen upper edge of the beam (cut-off) at the horizontal lamp centerline ± 50 mm (2 in.). Horizontal aim is preset and can not be adjusted. The high beam pattern should be correct when the low beams are aligned properly (Fig. 19). To adjust headlamp vertical alignment, rotate adjustment screw to achieve the specified low beam cut-off location. (4) Verify proper tire inflation. (5) Clean headlamp lenses. (6) Verify that luggage area is loaded as the vehicle is routinely used. (7) Fuel tank should be FULL. Add 2.94 kg (6.5 lbs.) of weight over the fuel tank for each estimated gallon of missing fuel. ALIGNMENT SCREEN PREPARATION (1) Position vehicle on a level surface perpendicular to a flat wall 10 meters (32.8 ft.) away from front of headlamp lens (Fig. 20). (2) If necessary, tape a line on the floor 10 meters (32.8 ft.) away from and parallel to the wall. (3) Rock vehicle side-to-side three times and allow suspension to stabilize. (4) Jounce front suspension three times by pushing downward on front bumper and releasing. (5) Measure the distance from the center of headlamp lens to the floor. Transfer measurement to the alignment screen (with tape). Use this line for up/down adjustment reference. HEADLAMP UNIT ADJUSTMENT Fig. 19 HEADLAMP ADJUSTMENT 1 - ADJUSTMENT LOCATION 2 - HEADLAMP UNIT STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT - EXPORT HEADLAMP UNIT ALIGNMENT PREPARATION (1) Verify headlamp dimmer switch and high beam indicator operation. (2) Verify that the headlamp leveling switch is in the “0” position. (3) Inspect and correct damaged or defective components that could interfere with proper headlamp alignment. The low beam headlamp will project on the screen upper edge of the beam (cut-off) at the horizontal lamp centerline ± 20 mm (0.75 in.). The high beam pattern should be correct when the low beams are aligned properly (Fig. 21). To adjust headlamp alignment, rotate adjustment screws to achieve the specified low beam cut-off location. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the three retaining screws (Fig. 22). (3) Disconnect the wiring harness from the bulbs (Fig. 23). (4) Remove wire harness retainer from back of headlamp unit. (5) Remove the headlamp unit. 8L - 20 LAMPS/LIGHTING - EXTERIOR RS HEADLAMP UNIT (Continued) Fig. 20 HEADLAMP UNIT ALIGNMENT SCREEN - EXPORT 1 2 3 4 - CENTER OF VEHICLE CENTER OF HEADLAMPS 15° CUT-OFF LINE FRONT OF HEADLAMP 5 - 10 METERS (32.8 FT.) 6 - HORIZONTAL CUT-OFF LINE 7 - 110 mm (4.3 in.) Fig. 22 HEADLAMP UNIT FASTENERS 1 - HEADLAMP UNIT RETAINING SCREW 2 - HEADLAMP UNIT Fig. 21 HEADLAMP UNIT ADJUSTMENT 1 - HEADLAMP ADJUSTMENT - HORIZONTAL 2 - HEADLAMP ADJUSTMENT - VERTICAL INSTALLATION (1) Reconnect wire harness to the bulbs. (2) Install wire harness retainer to headlamp unit. (3) Install the three retaining screws. LAMPS/LIGHTING - EXTERIOR RS 8L - 21 HEADLAMP UNIT (Continued) Fig. 25 LICENSE PLATE LAMP - REMOVE/INSTALL 1 - LICENSE PLATE LAMP UNIT 2 - BULB Fig. 23 HEADLAMP UNIT 1 2 3 4 - HEADLAMP UNIT HEADLAMP PARK/TURN SIGNAL LAMP WIRE HARNESS RETAINER (4) Reconnect the battery negative cable. LICENSE LAMP REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove two screws (Fig. 24). INSTALLATION (1) (2) (3) (4) Push bulb into socket. Install socket into lamp. Install two screws. Reconnect the battery negative cable. MULTI-FUNCTION SWITCH DESCRIPTION - TURN SIGNAL SYSTEM The turn signals are actuated with a lever on Multi-Function Switch, located on the left side of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The multi-function switch is a resistive MUX switch that feeds inputs to the BCM. OPERATION - TURN SIGNAL SYSTEM Fig. 24 LICENSE PLATE LAMP UNITS 1 - SCREW 2 - LICENSE PLATE LAMP (3) Twist bulb socket and remove (Fig. 25). (4) Pull bulb from socket. Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: • Multi-function switch • Body Control Module • Integrated Power Module (IPM) • Turn indicator lamp • Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. 8L - 22 LAMPS/LIGHTING - EXTERIOR RS MULTI-FUNCTION SWITCH (Continued) DIAGNOSIS AND TESTING - MULTI-FUNCTION SWITCH To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: (1) Remove the multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal, and Installation. (2) Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH RESISTANCE table. MULTI-FUNCTION SWITCH RESISTANCE SWITCH POSITION PIN NUMBER RESISTANCE LEFT 2 AND 3 1.7 V ± 5% RIGHT 2 AND 3 1K V ± 5% OPTICAL HORN 1 AND 3 4.87K V ± 5% HI BEAM 1 AND 3 2.32K V ± 5% Fig. 26 PARK/TURN SIGNAL LAMP 1 - PARK/TURN SIGNAL LAMP 2 - LAMP SOCKET (3) Install headlamp retaining screws. (4) Reconnect battery negative cable. REMOVAL (1) Disconnect and isolate battery negative cable. (2) Remove upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Removal. (3) Disconnect wire connector from back of multifunction switch. (4) Remove screws holding multi-function switch to steering column adapter collar. (5) Remove the multi-function switch. PARK/TURN SIGNAL LAMP EXPORT REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the headlamp unit. (3) Twist bulb socket and remove from headlamp unit (Fig. 27). INSTALLATION (1) Position the switch on to the steering column. (2) Install the two retaining screws. (3) Connect the wire harness connector. (4) Install the upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Installation. (5) Connect the battery negative cable. PARK/TURN SIGNAL LAMP REMOVAL (1) (2) (3) (Fig. (4) Disconnect and isolate battery negative cable. Remove headlamp retaining screws. Twist socket counter - clockwise and remove 26). Pull bulb from socket. Fig. 27 PARK/TURN SIGNAL LAMP 1 - LOW BEAM HEADLAMP 2 - PARK/TURN SIGNAL LAMP INSTALLATION (1) Push bulb into socket. (2) Twist socket into headlamp. (4) Twist bulb and remove from bulb socket. LAMPS/LIGHTING - EXTERIOR RS 8L - 23 PARK/TURN SIGNAL LAMP - EXPORT (Continued) INSTALLATION (1) (2) (3) (4) Install bulb to bulb socket. Install bulb socket to headlamp unit. Install headlamp unit. Connect battery negative cable. REAR FOG LAMP - EXPORT DESCRIPTION The rear fog lamps are incorporated into the tail lamp unit. (Refer to 8 - ELECTRICAL/LAMPS/ LIGHTING - EXTERIOR/TAIL LAMP - REMOVAL) for service procedures. REPEATER LAMP - EXPORT Fig. 28 TAIL LAMP SOCKET 1 - LAMP SOCKET 2 - TAIL LAMP UNIT (4) Reconnect the battery negative cable. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Push the side repeater lamp to one side and release retaining tab. (3) Pull side repeater lamp out and disengage bulb socket from lamp. (4) Depress, then rotate and pull bulb from socket. INSTALLATION (1) Install bulb to socket. (2) Push lamp socket into the side repeater lamp. (3) Position side repeater lamp to hole in fender. (4) Push side repeater lamp to one side and seat retaining tab into fender. (5) Connect battery negative cable. TAIL LAMP - EXPORT REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the tail lamp unit (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING EXTERIOR/TAIL LAMP UNIT - REMOVAL). (3) Squeeze the tabs on housing retaining the bulbs and remove from the tail lamp unit (Fig. 29). TAIL LAMP REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the tail lamp unit. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING EXTERIOR/TAIL LAMP UNIT - REMOVAL). (3) Squeeze the tabs on the bulb socket and remove from tail lamp unit (Fig. 28). (4) Pull bulb from lamp socket. INSTALLATION (1) Push bulb into the lamp socket. (2) Install bulb socket into the tail lamp unit. Ensure that both retaining tabs engage with an audible click. (3) Install the tail lamp unit. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING EXTERIOR/TAIL LAMP UNIT - INSTALLATION). Fig. 29 TAIL LAMP BULBS 1 2 3 4 5 - TAIL LAMP UNIT BRAKE/PARK LAMP TURN SIGNAL LAMP BACK UP LAMP REAR FOG LAMP (4) Remove bulbs by depressing, then turning counter-clockwise. 8L - 24 LAMPS/LIGHTING - EXTERIOR RS TAIL LAMP - EXPORT (Continued) INSTALLATION (1) Install bulbs by turning clockwise. (2) Install housing to tail lamp unit. (3) Install the tail lamp unit (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING EXTERIOR/TAIL LAMP UNIT - INSTALLATION). (4) Connect the battery negative cable. (4) Disengage hook attaching forward end of lamp to quarter panel opening. (5) Disconnect wire harness connector from tail lamp unit by sliding the red lock, then pressing release tab (Fig. 31). TAIL LAMP UNIT REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Raise the liftgate. (3) Remove the two retaining fasteners by prying under the head of the fastener with a flat bladed tool (Fig. 30). Fig. 31 TAIL LAMP UNIT - REMOVE/INSTALL 1 - WIRE HARNESS CONNECTOR 2 - TAIL LAMP UNIT INSTALLATION Fig. 30 TAIL LAMP UNIT FASTENERS 1 - TAIL LAMP UNIT FASTENER 2 - TAIL LAMP UNIT (1) Reconnect wire harness connector to the tail lamp. Slide lock into position. (2) Place lamp into position on quarter panel. (3) Engage hook attaching forward end of lamp to quarter panel. (4) Insert the two retaining fasteners by pressing into position. Ensure that the head of the fastener is open before inserting. (5) Close the liftgate. (6) Reconnect the battery negative cable. LAMPS/LIGHTING - INTERIOR RS 8L - 25 LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page LAMPS/LIGHTING - INTERIOR SPECIFICATIONS INTERIOR LAMPS . . . . . . . . . . CENTER CONSOLE LAMP SWITCH REMOVAL . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . CLUSTER ILLUMINATION LAMPS REMOVAL . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . COURTESY LAMP REMOVAL . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . DOME LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . 26 . . . . . . . . . . . 26 . . . . . . . . . . . 26 . . . . . . . . . . . 26 . . . . . . . . . . . 26 . . . . . . . . . . . 26 page INSTALLATION . . . . . . . . GLOVE BOX LAMP SWITCH REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . LIFTGATE LAMP REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . READING LAMP REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . VANITY LAMP REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . 26 LAMPS/LIGHTING - INTERIOR SPECIFICATIONS INTERIOR LAMPS BULB APPLICATION TABLE LAMP . . . . . . . . . . . . . . . . . 26 BULB LAMP BULB LIFTGATE 578 LIFTGATE AJAR LED LOW FUEL INDICATOR LED LOW WASHER FLUID INDICATOR LED MIL (BASE CLUSTER) LED MIL PC74 ABS LED AIRBAG LED OIL INDICATOR (BASE CLUSTER) LED ALARM SET PC74 OIL INDICATOR PC74 AUTOSTICK VFD* OVERHEAD CONSOLE READING PC579 BRAKE SYSTEM WARNING LED OVERDRIVE OFF INDICATOR CONSOLE 194 READING 578 VFD* CRUISE INDICATOR VFD* SEAT BELT INDICATOR LED DOME/RAIL LAMPS 578 TEMPERATURE INDICATOR LED DOOR AJAR INDICATOR LED TRAC OFF INDICATOR VFD* DOOR COURTESY LAMP 578 FRONT DOOR COURTESY 567 TURN SIGNAL INDICATOR (BASE CLUSTER) LED GLOVE BOX 194 TURN SIGNAL INDICATOR PC74 HIGH BEAM INDICATOR (BASE CLUSTER) LED HIGH BEAM INDICATOR PC74 CLUSTER ILLUMINATION PC74 VISOR VANITY VOLTAGE INDICATOR 6501966 LED * VFD = VACUUM FLUORESCENT DISPLAY 8L - 26 LAMPS/LIGHTING - INTERIOR RS CENTER CONSOLE LAMP SWITCH REMOVAL (1) (2) (3) (4) Disconnect and isolate the battery negative cable. Open console lid and remove tray. Using a flat bladed tool, pry up on the switch. Remove bulb from switch. INSTALLATION (1) (2) (3) (4) Install bulb into switch. Push switch into console opening. Install tray and close lid. Connect battery negative cable. CLUSTER ILLUMINATION LAMPS REMOVAL Fig. 1 COURTESY LAMP 1 - WIRE HARNESS 2 - COURTESY LAMP (2) Using a flat bladed tool, pry off the lamp lens. (3) Remove bulb from lamp. INSTALLATION (1) Remove the Instrument Cluster. Refer to Electrical, Instrument Cluster, Removal. (2) Turn over cluster and expose the illumination bulb sockets. (3) Identify which bulb is defective and twist it out of the cluster using a counterclockwise motion. GLOVE BOX LAMP SWITCH INSTALLATION REMOVAL (1) Install the new bulb socket into the cluster using a clockwise motion. (2) Install the Instrument Cluster. Refer to Electrical, Instrument Cluster, Installation. (1) Disconnect and isolate the battery negative cable. (2) Open glove box door. (3) Push switch through from behind (Fig. 2). (1) Install bulb to lamp. (2) Press lens into place. (3) Connect battery negative cable. COURTESY LAMP REMOVAL (1) (2) (Fig. (3) (4) Disconnect and isolate the battery negative cable. Using a trim stick, pry lamp from door panel 1). Disconnect wire harness from the lamp. Remove lens from the lamp and remove bulb. INSTALLATION (1) (2) (3) (4) Install bulb and lens to lamp. Reconnect wire harness to lamp. Press lamp into the door panel. Reconnect battery negative cable. DOME LAMP REMOVAL (1) Disconnect and isolate the battery negative cable. Fig. 2 GLOVE BOX LAMP/SWITCH 1 - GLOVE BOX BULB 2 - GLOVE BOX LAMP SWITCH (4) Disconnect wire harness from switch. (5) Pull bulb from switch. LAMPS/LIGHTING - INTERIOR RS 8L - 27 GLOVE BOX LAMP SWITCH (Continued) INSTALLATION (1) (2) (3) (4) (5) Push bulb into switch. Connect wire harness to switch. Push switch into instrument panel. Close glove box door. Reconnect the battery negative cable. LIFTGATE LAMP REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Using a flat bladed tool, pry lamp from trim panel (Fig. 3). READING LAMP REMOVAL The front reading lamps are incorporated into the overhead console. If the reading lamps require replacement, the overhead console must be replaced. (Refer to 8 - ELECTRICAL/OVERHEAD CONSOLE REMOVAL). The rear reading lamps are incorporated into the assist handle. If the rear reading lamps require replacement, the assist handle must be replaced. (Refer to 23 - BODY/INTERIOR/ASSIST HANDLE - REMOVAL). The bulbs can be serviced separately. (1) Disconnect and isolate the battery negative cable. (2) Using a flat bladed tool, pry off the lamp lens (Fig. 4), (Fig. 5). Fig. 3 LIFTGATE LAMP 1 - LIFTGATE LAMP 2 - WIRE HARNESS (3) Disconnect wire harness connector from lamp. (4) Pry off lens and remove bulb. INSTALLATION (1) Install bulb and snap lens into place. (2) Reconnect wire harness connector to lamp. (3) Position lamp onto trim panel and snap into place. (4) Reconnect battery negative cable. Fig. 4 OVERHEAD CONSOLE 1 - LAMP LENS 2 - OVERHEAD CONSOLE 8L - 28 LAMPS/LIGHTING - INTERIOR RS READING LAMP (Continued) (3) Remove bulb from lamp (Fig. 6), (Fig. 7). Fig. 5 COURTESY/READING LAMP 1 - HVAC LOUVER 2 - ASSIST HANDLE 3 - LAMP LENS Fig. 7 COURTESY/READING LAMP 1 - COURTESY/READING LAMP (1) Disconnect and isolate the battery negative cable. (2) Using a pick or other suitable tool, pry the lens from the lamp (Fig. 8). Fig. 6 OVERHEAD CONSOLE LAMP 1 - LAMP 2 - OVERHEAD CONSOLE INSTALLATION (1) Install bulb to lamp. (2) Press lens into place. (3) Reconnect the battery negative cable. VANITY LAMP REMOVAL The vanity lamp is incorporated into the visor assembly. If the vanity lamp needs to be replaced, the entire visor must be replaced. The bulbs are serviced separately. Fig. 8 VANITY LAMP 1 - VISOR 2 - VISOR/VANITY LAMP 3 - LENS (3) Remove bulb. INSTALLATION (1) Install bulb. (2) Snap lamp lens into position. (3) Connect the battery negative cable. POWER SYSTEMS RS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LIFTGATE SYSTEM . . . . . . . . . . . . . . . . . . 1 POWER SLIDING DOOR SYSTEM . . . . . . . . . . . . 18 POWER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . 46 POWER SEAT SYSTEM. . . . . . . . . . . . . . . . . . . . . 51 POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . 64 POWER LIFTGATE SYSTEM TABLE OF CONTENTS page POWER LIFTGATE SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DIAGNOSIS AND TESTING - POWER LIFTGATE SYSTEM . . . . . . . . . . . . . . . . . . . . . 4 STANDARD PROCEDURE STANDARD PROCEDURE - LIFTGATE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 8 STANDARD PROCEDURE - POWER LIFTGATE LEARN CYCLE . . . . . . . . . . . . . . . . 9 PINCH SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FULL OPEN SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 LIFTGATE MOTOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 ENGAGE ACTUATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 page TRANSVERSE BRACKET DESCRIPTION . . . . . . . . . OPERATION . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION . . . . . . . . . LIFT GEAR & LINK ROD DESCRIPTION . . . . . . . . . OPERATION . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION . . . . . . . . . LATCH DESCRIPTION . . . . . . . . . OPERATION . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION . . . . . . . . . LATCH ACTUATOR DESCRIPTION . . . . . . . . . OPERATION . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION . . . . . . . . . EXTERIOR HANDLE SWITCH DESCRIPTION . . . . . . . . . OPERATION . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION . . . . . . . . . CHIME/THERMISTOR DESCRIPTION . . . . . . . . . OPERATION . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . 12 . 13 . 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . 14 . 14 . 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . 15 . 15 . 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . 15 . 15 . 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . 16 . 16 . 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . 17 . 17 . 17 8N - 2 POWER LIFTGATE SYSTEM RS POWER LIFTGATE SYSTEM DESCRIPTION Fig. 1 POWER LIFTGATE INTRODUCTION Some vehicles are equipped with an automatic opening and closing power liftgate system (Fig. 1). This power liftgate system is a complex system consisting of many components. Some of these components are the liftgate gear motor assembly, latch assembly, lift gear and rod, liftgate control module, chime/thermistor, full open switch, engage actuator, pinch sensor, liftgate handle switch, overhead console switch, key fob switches (Fig. 2), pawl switch and ratchet switch. The power liftgate system has its own door control module, located on the vehicles left body D-pillar behind the trim panel. (Refer to 8 - ELECTRICAL/ ELECTRONIC CONTROL MODULES/DOOR CONTROL MODULE - DESCRIPTION) The power liftgate gear motor assembly is located just above the control module. The latch assembly is located in the bottom center of the power liftgate, below the exterior liftgate handle switch. The power liftgate full open switch, engage actuator, lift gear and rod are part of the liftgate gear motor assembly. The pawl and ratchet switches are part of the latch assembly. The pinch sensor or sensors are located along the right and left sides of the power liftgate, just above the body line. The liftgate handle switch is an power release switch and is located in the rear light bar assembly, just above the license plate. The overhead console switch is an power open and close command switch located in the vehicles overhead console. Safety is of the utmost concern with the power liftgate system. Software technology has enabled the power liftgate control module to detect resistance to liftgate travel, which allows the power liftgate to stop and reverse direction anytime an obstruction is felt or any of the command switches are operated (only in closing direction). Battery voltage is supplied to the power liftgate system through a 40 amp fuse, located in the Intelligent Power Module (IPM) assembly (Fig. 3). In the unlikely event that the power liftgate system develops a fault the power liftgate can still be operated manually with a key, just like a standard manual liftgate. POWER LIFTGATE SYSTEM RS 8N - 3 POWER LIFTGATE SYSTEM (Continued) the power liftgate control module via the PCI bus circuit. A diagnostic scan tool, such as the DRB IIIt is used to read and troubleshoot these Diagnostic Trouble Codes (DTC). Refer to the Body Diagnostic Manual for a complete list of diagnostic routines. For additional information refer to Power Liftgate Operation. For a complete system wiring schematic refer to Wiring Diagrams. For system operation instructions refer to the vehicles owner manual. Refer to the Body section of the service manual for additional information on liftgate components such as the prop rods, hinges, door alignment and striker alignment. WARNING: BE CERTAIN TO READ ALL WARNINGS AND CAUTIONS (NOTED BELOW) IN POWER LIFTGATE SYSTEM OPERATION BEFORE ATTEMPTING ANY SERVICE OF THE POWER LIFTGATE SYSTEM OR COMPONENTS. OPERATION Fig. 2 KEY FOB 1 - Left Sliding Door Switch 2 - Right Sliding Door Switch 3 - Liftgate Switch Fig. 3 LIFTGATE FUSE LOCATION The power liftgate control module communicates on the J1850 Programmable Communication Interface (PCI) Bus Circuit. Therefore, the power liftgate control module can generate and store its own Diagnostic Trouble Codes (DTC). The vehicles Body Control Module (BCM) receives and supplies messages to With the push of a power liftgate open/close command switch (key fob or overhead console mounted) a signal is sent out on the J1850 PCI Data Bus circuit. This signal is detected at the body control module (BCM). The BCM then sends a signal out on the J1850 PCI Data Bus circuit to the power liftgate module. The power liftgate module then signals the power liftgate motor to start an open or close cycle, depending on what position the liftgate is in open or closed. During a liftgate open or close cycle, if the power liftgate module detects sufficient resistance to liftgate travel, such as an obstruction in the liftgates path, the power liftgate control module will immediately stop the liftgate movement and reverse travel to the full open or closed position. The ability for the power liftgate module to detect resistance to liftgate travel is accomplished by hall effect sensors, drive motor speed and pinch sensors (tape switches). The power liftgate control module has the ability to learn. Anytime the liftgate is opened or closed using the power liftgate system the module learns from its cycle. If a replacement power liftgate component is installed or a liftgate adjustment is made, the module will relearn the effort and/or time required to open or close the door. This learn cycle can be performed with a Diagnostic Scan Tool, such as the DRB IIIt or with a complete cycle of the liftgate, using any one of the command switches. Refer to Standard Procedures in this section for detailed instructions. 8N - 4 POWER LIFTGATE SYSTEM RS POWER LIFTGATE SYSTEM (Continued) The power liftgate system is designed with a number of system inhibitors. These inhibitors are necessary for safety and / or feasibility of the power liftgate system. Refer to power liftgate system inhibitors noted below: POWER LIFTGATE SYSTEM INHIBITORS • The Power Liftgate may not operate in extreme temperatures. These extreme temperatures will be approximately -12° F (-24.4° C) on the low side and 143° F (61.6° C) for the high side. A chime/thermister assembly in the rear light bar assembly monitors the outside temperature. • The vehicles transmission must be in park or neutral for the power liftgate to start a cycle. • If multiple obstacles are detected during the same power open or close cycle the liftgate goes into manual operation. • If severe Diagnostic Trouble Codes (DTC) are stored in the power liftgate control module. POWER LIFTGATE SYSTEM CAUTIONS AND WARNINGS WARNING: ALWAYS DISCONNECT THE NEGATIVE BATTERY CABLE BEFORE ATTEMPTING ANY POWER LIFTGATE SYSTEM SERVICE. WARNING: THERE IS A SMALL AREA ON BOTH SIDES OF THE LOWER POWER LIFTGATE WHICH ARE NOT PROTECTED BY PINCH SENSORS. EXTREME CARE MUST BE TAKEN TO PREVENT OBJECTS FROM ENTERING THIS AREA ONCE THE LIFTGATE REACHES THE SECONDARY LATCH CONTACT (APPROXIMATELY 1/2 INCH BEFORE FULLY CLOSED). WARNING: NEVER ATTEMPT TO ENTER OR EXIT THE VEHICLE WITH THE LIFTGATE IN MOTION. YOU COULD DAMAGE THE POWER LIFTGATE SYS- TEM AND/OR COMPONENTS AND/OR CAUSE PERSONAL INJURY. WARNING: NEVER STICK OBJECTS IN THE POWER LIFTGATE WHEN CINCHING CLOSED. YOU COULD DAMAGE THE VEHICLE, POWER LIFTGATE SYSTEM COMPONENTS AND/OR CAUSE PERSONAL INJURY. DIAGNOSIS AND TESTING - POWER LIFTGATE SYSTEM The power opening and closing power liftgate system is a complex system containing many components and modules. In order to obtain conclusive testing the Programmable Communications Interface (J1850) data bus network and all of the electronic modules that provide inputs to, or receive outputs from the power liftgate system must be checked. The power liftgate system was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB IIIt. The most reliable, efficient, and accurate means to diagnose the power liftgate system requires the use of a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual. The DRB IIIt can be used to observe various switch statuses throughout the power liftgate system to help the technician diagnose a defective switch or component. The DRB IIIt can also be used to actuate various components throughout the power liftgate system to help the technician diagnose a defective component. Before any testing of the power liftgate system is attempted, the battery should be fully charged, all built-in power liftgate system inhibitors read and understood (Refer to power liftgate system operation) and all wire harness and ground connections inspected around the affected areas on the vehicle. Following are quick reference diagnostic tables to help when diagnosing and testing the power liftgate system. POWER LIFTGATE SYSTEM RS 8N - 5 POWER LIFTGATE SYSTEM (Continued) LIFTGATE SYSTEM DIAGNOSIS CONDITION Liftgate opens unexpectedly POSSIBLE CAUSES CORRECTION Failure of Power Liftgate or Body Control module Disconnect then reconnect battery to reset module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of latch assembly Check wiring connections and for blown fuse Check for trouble codes, replace latch if necessary Liftgate will not open from outside of vehicle manually Failure of open/close command switch Check for shorted or defective switch Failure of key cylinder assembly Check for broken key cylinder assembly Check link rod connections at the latch and key cylinder assembly Check for binds or kinks in link rod Check for foreign matter preventing the operation of key cylinder assembly Replace the necessary components Failure of latch assembly Check wire connections and for blown fuse Check for foreign matter preventing the operation of latch assembly Replace latch assembly, if necessary Binding or sticking of components Check for foreign matter preventing the operation of door Establish location of binding Replace necessary components Liftgate will not open/close under power Failure of Power Liftgate or Body Control Module Disconnect then reconnect battery to reset module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of latch assembly Check wire connections and for blown fuse Check for foreign matter preventing the operation of latch assembly Troubleshoot using Body Diagnostic Manual Replace latch assembly, if necessary Failure of motor assembly Troubleshoot using Body Diagnostic Manual Failure of full open switch Troubleshoot using Body Diagnostic Manual 8N - 6 POWER LIFTGATE SYSTEM RS POWER LIFTGATE SYSTEM (Continued) CONDITION Power loss during Liftgate operation No power latching in primary and/or secondary positions POSSIBLE CAUSES CORRECTION Binding or sticking of components Establish location of binding and replace necessary components Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Low battery voltage Charge battery Failure of Power Liftgate or Body Control Module Disconnect then reconnect battery to reset module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of motor assembly Check for no drive condition Failure of latch assembly Check wire connections and for blown fuse Check for foreign matter preventing the operation of latch assembly Troubleshoot using Body Diagnostic Manual. Replace latch assembly, if necessary Latch will not fully release from primary position Binding or sticking of components Establish location of binding and replace necessary components Failure of Power Liftgate or Body Control Module Disconnect then reconnect battery to reset module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Door seal force too high Inspect seals for damage, mis-assembly, foreign matter or other possible obstruction Failure of motor assembly Check for no drive condition Failure of latch assembly Check wire connections and for blown fuse Check for foreign matter or damaged components preventing the operation of latch assembly Troubleshoot using body electrical troubleshooting manual Replace latch assembly, if necessary Failure of outside handle switch Troubleshoot using Body Diagnostic Manual Replace switch, if necessary Failure of Power Liftgate or Body Control Module Disconnect then reconnect battery to reset module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Binding or sticking of components Establish location of binding and replace necessary components POWER LIFTGATE SYSTEM RS 8N - 7 POWER LIFTGATE SYSTEM (Continued) CONDITION Key fob, Outside Handle or overhead console switches do not power operate liftgate POSSIBLE CAUSES CORRECTION Blown Fuse Check fuse and replace Battery voltage low Charge or replace battery in key fob or vehicle Failure of latch assembly Check for foreign matter preventing the operation of latch assembly Check wire connection Pawl and/or ratchet switch inoperative Replace latch if necessary Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Failure of Body Control Module (BCM) Check electrical connections Refer to the Body electrical troubleshooting guide for additional checks Replace BCM if necessary Failure of key fob Reprogram key fob Replace key fob if necessary Failure of Power Liftgate Module Disconnect then reconnect battery to reset module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of liftgate motor assembly Check for foreign matter preventing the operation of gear motor assembly Check wire connections Motor clutch does not engage, replace assembly Full open switch inoperative, replace switch, if necessary Troubleshoot using Body Diagnostic Manual Replace motor, if necessary Liftgate does not stay open Failure of liftgate prop rods Replace prop rods, if necessary Check for broken attachments High inside/outside opening effort Failure of liftgate prop rods Replace prop rods, if necessary Check for broken attachments Gear motor did not disengage Troubleshoot using Body Diagnostic Manual Replace components, if necessary Binding or sticking of components Establish location of binding and replace necessary components 8N - 8 POWER LIFTGATE SYSTEM RS POWER LIFTGATE SYSTEM (Continued) CONDITION Liftgate continues to cinch closed during power mode POSSIBLE CAUSES Failure of latch assembly CORRECTION Check wire connections and for blown fuse Check for foreign matter preventing the operation of latch assembly Troubleshoot using Body Diagnostic Manual Replace components, if necessary Liftgate continues to open during power mode (runaway motor) Failure of Power Liftgate or Body Control Module Disconnect then reconnect battery to reset module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Failure of Power Liftgate or Body Control Module Disconnect then reconnect battery to reset module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of full open switch Check wire connections Replace switch, if necessary Liftgate opens very slowly Failure of motor assembly Check for continuous drive condition Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to Wiring Diagrams Failure of liftgate motor assembly Check wire connections Replace motor assembly, if necessary Squeaks, Noises and rattles Failure of liftgate prop rods Replace prop rods, if necessary Binding or sticking of components Establish location of binding and replace necessary components Grade of vehicle too steep for power operation Operate liftgate manually Foreign material in door compartment Remove foreign material Loose components Check and tighten loose components STANDARD PROCEDURE STANDARD PROCEDURE - LIFTGATE ADJUSTMENT In order for the power liftgate system to function properly the liftgate must move freely and smoothly. The power liftgate system can acommodate for some minor changes in the effort required to move the liftgate. However, in extreme conditions the liftgate may need to be mechanicaly adjusted for proper fit and finish. Refer to the Liftgate Adjustment procedure in the Body section of the service manual for detailed instructions. If a problem exists with the power liftgate and it is suspected to be extreme effort check the liftgate prop rods and hinges for free movement. Use a known good vehicle for liftgate effort comparison. NOTE: Routine application of Mopar MP-50T or equivalent on the chrome prop rod shafts and liftgate latch and hinges will help keep the liftgate in good working order. POWER LIFTGATE SYSTEM RS 8N - 9 POWER LIFTGATE SYSTEM (Continued) STANDARD PROCEDURE - POWER LIFTGATE LEARN CYCLE Any time a power liftgate component is removed, replaced or a liftgate adjustment is performed a learn cycle must be performed. This learn cycle enables the power liftgate control module to learn or relearn information (travel limits, resistance to door travel, etc.) which allows it to perform properly and safely. To perform a learn cycle do the following: (1) Obtain a DRB IIIt scan tool. (2) Connect the DRB IIIt to the vehicle and check for any power liftgate system stored trouble codes, correct and erase any stored codes. (3) Using the DRB IIIt, Go into Test Routine Menu and select the power open command. (4) Select the power close command. (5) The liftgate learn cycle is complete. If a DRB IIIt scan tool is not available the learn cycle can be performed by actuating the liftgate by using any of the normal command switches. Be certain to cycle the liftgate through a complete open and close cycle before returning the vehicle to service. NOTE: If the power liftgate will not complete a full cycle a problem exists with the power liftgate system. (Refer to 8 - ELECTRICAL/POWER DOORS DIAGNOSIS AND TESTING). PINCH SENSOR DESCRIPTION Vehicles equipped with a power liftgate utilize two pinch sensors, one is located on each side of the liftgate (Fig. 4). These sensors look like weather-strips, however they consist of pieces of electrically conductive rubber (tapeswitch), wires, resistor, double sided tape, and a plastic carrier. They are used to indicate an obstruction during a power close cycle. OPERATION During a power liftgate close cycle, if either of the two conductive rubber strips (tapeswitch) of the pinch sensor come in contact with an obstacle, the pinch sensor circuit is completed. This tells the power liftgate control module that a obstruction is felt. The control module will stop the liftgate immediately and return it to the full open position. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove trim panel from liftgate. Refer to Body for the procedure. Fig. 4 PINCH SENSOR LOCATION 1 2 3 4 5 - LIFTGATE PINCH SENSOR ASSEMBLY POWER LIFTGATE LINK ROD PINCH SENSOR WIRE HARNESS CONNECTOR PINCH SENSOR WIRE HARNESS (3) Disconnect the pinch sensor wire harness connector (Fig. 4). (4) Remove screws holding the pinch sensor to liftgate. (5) Feed the pinch sensor wire harness out of the liftgate and remove the sensor from the vehicle. INSTALLATION (1) Position the pinch sensor and install screws holding the sensor to the liftgate. Torque screws to 25 in. lbs. (2) Install wire harness grommet in liftgate flange and route, connect the pinch sensor wire harness connector. (3) Install the trim panel on the liftgate. Refer to the Body section for the procedure. (4) Connect the negative battery cable. (5) Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the pinch sensor. (6) Verify power liftgate system and pinch sensor operation. Cycle the power liftgate through one complete open and close cycle, during the final close cycle press the pinch sensor to verify the power liftgate detects an obstruction and returns to the full open position. 8N - 10 POWER LIFTGATE SYSTEM RS PINCH SENSOR (Continued) WARNING: USE EXTREME CAUTION WHEN TESTING PINCH SENSOR OPERATION. FULL OPEN SWITCH DESCRIPTION (2) Remove the lift gear and link rod assembly from the vehicle(Refer to 8 - ELECTRICAL/POWER DOORS/CONTROL ROD - REMOVAL). (3) Cut the two wires leading to the full open switch or back the wires out of the electrical connector (Fig. 5). Refer to the Wiring section of the service manual for detailed instructions. (4) Remove the full open switch retaining screw and remove the full open switch from the gear motor housing assembly. INSTALLATION Fig. 5 FULL OPEN SWITCH LOCATION 1 - FULL OPEN SWITCH 2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3) Vehicles equipped with a power liftgate utilize a full open switch. This switch is located on the gear motor housing (Fig. 5) and is used to signal the power liftgate module when the liftgate is in the full open position. Two wires are used from the full open switch contacts to the gear motor assemblies main electrical connector. The full open switch is a serviceable component. Consult your Mopar parts catalog for a specific part number. OPERATION When the power liftgate reaches the full open position, the gear motor housing mounted full open switch electrical contacts come in contact with each other. This sends a ground signal to the power liftgate control module, telling the module that the liftgate has reached the full open position. REMOVAL (1) Disconnect and isolate the negative battery cable. (1) Perform a wiring repair on the full open switch wires following the approved procedure in the Wiring section of the service manual. Or install new terminals on the wire ends and reinstall in the main liftgate motor electrical connector. (2) Position and install the full open switch retaining screw. (3) Install the power liftgate lift gear and link rod assembly. (Refer to 8 - ELECTRICAL/POWER DOORS/CONTROL ROD - INSTALLATION) (4) Connect the negative battery cable. (5) Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes. (6) Verify power liftgate system and full open switch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. LIFTGATE MOTOR DESCRIPTION Vehicles equipped with a power liftgate, utilize a liftgate gear motor assembly (Fig. 6). The gear motor assembly consists of a DC motor, hall effect sensor, engage actuator, full open switch, lift gear, aluminum housing, drive gears and wire harness. The gears and motor portion of the assembly provides the power and torque required to open or close the liftgate under the worst case conditions. The hall effect sensor is used to provide the liftgate control module with a speed reading, which is used to monitor the resistance of liftgate travel. This speed reading also allows the power liftgate control module to detect obstructions and move the liftgate accordingly. The engage actuator is used to toggle between power open/close mode and full manual mode when desired. The full open switch is used to let the power liftgate control module know when the liftgate is approaching the full open position. POWER LIFTGATE SYSTEM RS 8N - 11 LIFTGATE MOTOR (Continued) fer the remaining components (engage actuator, full open switch, transverse bracket and lift gear and rod) to the replacement motor assembly. (1) Disconnect and isolate the negative battery cable. (2) Remove the left rear D-pillar trim panel from the vehicle. Refer to the Body section for the procedure. (3) Disconnect the wire harness connector from the motor assembly (Fig. 6). (4) Remove the two bolts from the motor housing and the one bolt from the transverse mount bracket. (5) Grab the liftgate motor assembly and lift upward and out to unhook the motor assembly from the D-pillar. (6) Remove the liftgate motor assembly from the vehicle. INSTALLATION Fig. 6 POWER LIFTGATE COMPONENTS 1 - POWER LIFTGATE GEAR MOTOR ASSEMBLY 2 - POWER LIFTGATE CONTROL MODULE 3 - ELECTRICAL GROUND LOCATION Serviceable components of the power liftgate gear motor assembly are the complete gear motor assembly, motor and wire harness, lift gear and control rod, engage actuator, full open switch and the transverse bracket. Refer to additional information in this group for more component details. OPERATION With the push of a power liftgate command switch (liftgate closed), the power liftgate control module will signal the latch assembly to release the door from its primary closed and latched position to the released and movable position. The liftgate motor mounted, engage actuator then engages the liftgate motor assembly, which moves the liftgate into the open position. The liftgate motor provides the torque and power to move the door to its full open or closed position(Refer to 8 - ELECTRICAL/POWER DOORS OPERATION) for additional information. REMOVAL The power liftgate motor can be serviced in two different ways. The first of which is called out here, the complete gear motor assembly. The second way includes the motor, aluminum housing, drive gears and wire harness assembly. To perform this service procedure, use the following procedure to remove the gear motor assembly from the vehicle. Then refer to the other procedures called out this section to trans- (1) Using the motor housing tab, hook the liftgate motor assembly on the D-pillar. (2) Install the three motor assembly retaining bolts. Torque the two rear most bolts first to 9.5 N·m (85 in. lbs.). Torque the remaining bolt next to the window actuator to 9.5 N·m (85 in. lbs.). (3) Connect the liftgate motor assembly electrical connector. (4) Install the D-pillar trim panel on the vehicle. Refer to Body for the procedure. (5) Connect the negative battery cable. (6) Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes related to the door motor assembly. (7) Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. ENGAGE ACTUATOR DESCRIPTION Vehicles equipped with a power liftgate utilize a power liftgate engage actuator (Fig. 7). The 12 volt engage actuator provides the engagement and disengagement of the liftgate gear motor to the lift gear by way of an over center link, activated by a lever. The engage actuator is a serviceable component and cannot be repaired, if found to be faulty it must be replaced. OPERATION The engage actuators normal position is disengaged. When a power liftgate open or close command is generated from any of the command switches, the power liftgate control module signals the engage 8N - 12 POWER LIFTGATE SYSTEM RS ENGAGE ACTUATOR (Continued) Fig. 7 LIFTGATE GEAR MOTOR ASSEMBLY 1 2 3 4 - TRANSVERSE BRACKET ENGAGE ACTUATOR LIFT GEAR AND ROD ASSEMBLY LIFTGATE MOTOR actuator to move its lever to the engaged position. This engages the gear motor to the lift gear, so when the motor turns the lift gate moves upward or downwards depending on its current position. During a manual liftgate open or close cycle the engage actuator is disengaged, allowing unrestricted liftgate movement. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the left rear D-pillar trim from the vehicle. Refer to Body for the procedure. (3) Using your hand manually engage the actuator link rod, this must be done to access one of the engage actuator retaining screws. (4) Remove the two engage actuator retaining screws (Fig. 8). (5) Disconnect the engage actuator electrical connector and remove the engage actuator from the vehicle. INSTALLATION (1) Position the engage actuator and connect the engage actuator electrical connector. (2) Install the two engage actuator retaining screws. (3) Manually disengage the actuator. Fig. 8 LIFTGATE GEAR MOTOR ASSEMBLY 1 - ENGAGE ACTUATOR RETAINING SCREWS 2 - LIFT GEAR RETAINING BOLTS (4) Install the left rear D-pillar trim on the vehicle. Refer to Body for the procedure. (5) Connect the negative battery cable. (6) Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. (7) Verify power liftgate system and engage actuator operation. Cycle the power liftgate through one complete open and close cycle. TRANSVERSE BRACKET DESCRIPTION Vehicles equipped with a power liftgate utilize a transverse bracket (Fig. 9). This bracket is not different than any other metal bracket which is used to support and secure the power liftgate gear motor assembly to the vehicles left rear body D-pillar. The transverse bracket is a serviceable power liftgate component. Consult your Mopar™ parts catalog for a specific part number. OPERATION The power liftgate transverse bracket supports the gear motor assembly by supplying an additional attachment point. Located on the leading edge of the gear motor assembly, one end of the transverse bracket attaches to the motor assembly the other to the leading edge of the vehicles D-pillar. POWER LIFTGATE SYSTEM RS 8N - 13 TRANSVERSE BRACKET (Continued) (5) Connect the gear motor assembly electrical connector and engage retaining pushpin. (6) Install the appropriate D-pillar trim from the vehicle. Refer to Body for the procedure. LIFT GEAR & LINK ROD DESCRIPTION Fig. 9 LIFTGATE GEAR MOTOR ASSEMBLY 1 2 3 4 - TRANSVERSE BRACKET ENGAGE ACTUATOR LIFT GEAR AND ROD ASSEMBLY LIFTGATE MOTOR REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the left D-pillar trim from the vehicle. Refer to Body for the procedure. (3) Disconnect the gear motor assembly electrical connector and disengage retaining pushpin. (4) Loosen the gear motor assembly retaining bolts to allow room for transverse bracket to be removed. (5) Remove the transverse bracket retaining bolts (Fig. 10). (6) Remove the transverse bracket from the vehicle. INSTALLATION (1) Position the transverse bracket in the vehicle. Be certain the transverse bracket is properly positioned. The bracket should just touch the engage actuator arm and be positioned between the actuator arm and the motor housing. (2) Torque the transverse bracket retaining bolts to the gear motor assembly to 9.5 N·m (85 in. lbs.).. Do not tighten the transverse bracket retaining bolt, located under the window actuator at this time. (3) Torque the gear motor assembly retaining bolts to 9.5 N·m (85 in. lbs.).. (4) Torque the final transverse bracket retaining bolt to 9.5 N·m (85 in. lbs.). Fig. 10 LIFTGATE GEAR MOTOR ASSEMBLY 1 2 3 4 - TRANSVERSE BRACKET ENGAGE ACTUATOR LIFT GEAR AND ROD ASSEMBLY LIFTGATE MOTOR Vehicles equipped with a power liftgate utilize a lift gear and rod assembly. This lift gear and rod assembly are located in the left rear of the vehicle and are visible without removing the D-pillar trim (Fig. 10). The lift gear provides the leverage to move the liftgate from the closed to the open position. The lift gear attaches to a bearing on the gear motor assembly with four bolts. On the outboard side of the lift gear are rivited on teeth, which mesh with the gear motor assembly drive gears during a open or close operation. The rod assembly is a steel shaft, equipped with two spherical rod ends which attaches the lift gear to the liftgate. The lift gear and rod assembly are serviceable components. Consult your Mopar™ parts catalog for a part number. 8N - 14 POWER LIFTGATE SYSTEM RS LIFT GEAR & LINK ROD (Continued) OPERATION LATCH One end of the rod assembly is attached to the liftgate, the other attached to the lift gear. When the lift gear is driven by the gear motor assembly the liftgate is moved to the open or closed position. DESCRIPTION REMOVAL (1) Remove the left rear D-pillar trim from the vehicle. Refer to Body for the procedure. (2) Remove the lift gear retaining bolts (Fig. 11). Fig. 12 POWER LATCH ORIENTATION 1 2 3 4 Fig. 11 LIFTGATE GEAR MOTOR ASSEMBLY 1 - ENGAGE ACTUATOR RETAINING SCREWS 2 - LIFT GEAR RETAINING BOLTS (3) Remove the lift gear and rod from the vehicle. INSTALLATION (1) Position the lift gear assembly and install the retaining bolts. Torque the bolts to 28 N·m (21 ft. lbs.). (2) Install the left rear D-pillar trim on the vehicle. Refer to Body for the procedure. CAUTION: Torque link rod to liftgate attachment bolt to 250 in. lbs. Care must be taken not to overtorque link rod bolt. - LATCH & ACTUATOR ASSEMBLY LATCH ELECTRICAL CONNECTOR LOCK CYLINDER LINK ROD LIFTGATE LOCK CYLINDER Vehicles equipped with a power liftgate, utilize a power cinch/release latch. This latch performs the same features as a manual liftgate latch as well as the power cinch and / or release capability. A second type of power latch can also be found on some RS models, this latch is designed to perform a power release only. The power cinch and release capability is accomplished by an actuator mounted to the leading edge of the latch assembly. The latch is located in the lower center of the liftgate assembly (Fig. 12) and contains integral pawl and ratchet switches. The ratchet switch acts as a liftgate ajar switch. The power latch assembly can be serviced as a complete assembly, latch without actuator or just the actuator. Consult your Mopar parts catalog for specific part numbers. POWER LIFTGATE SYSTEM RS 8N - 15 LATCH (Continued) OPERATION On the power cinch/release latch, the latch mounted actuator provides the torque required to close the power liftgate from the secondary to the primary closed and latched position. On the power cinch/release latch and the power release only latch, the actuator releases the liftgate from the primary closed and latched position to the fully unlatched and movable position. REMOVAL (1) Open the hood, disconnect and isolate the negative battery cable. (2) Open the liftgate and remove the liftgate trim panel. Refer to Body for the procedure. (3) Disconnect the power latch electrical connector (Fig. 12). (4) Remove the power latch retaining bolts. (5) Disconnect the liftgate lock cylinder link rod from the key cylinder or latch assembly. To disconnect from latch, rotate the plastic retaining clip 90 ° to unsnap clip from linkrod. Then pull link rod straight out of latch arm. INSTALLATION (1) Connect the liftgate lock cylinder link rod on the cinch latch assembly. Rotate the plastic retaining clip 90 ° to lock retaining clip on linkrod. (2) Connect the link rod on the lock cylinder. (3) Install the power latch retaining bolts. Torque to 10 N·m (90 in. lbs.). (4) Connect the power latch electrical connector and secure push pin retainers. (5) Connect the negative battery cable. (6) Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the power latch. (7) Verify power liftgate system and power cinch / release latch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. (8) Verify power liftgate manual operation. Using liftgate key rotate the lock cylinder to verify door operation. Pull door open using exterior liftgate handle / switch. (9) Install the liftgate trim panel. Refer to Body for the procedure. LATCH ACTUATOR DESCRIPTION Vehicles equipped with a power liftgate utilize a power cinch latch or power release latch (Fig. 13). The power cinch and/or power release is made possi- Fig. 13 POWER LATCH ORIENTATION 1 2 3 4 - LATCH & ACTUATOR ASSEMBLY LATCH ELECTRICAL CONNECTOR LOCK CYLINDER LINK ROD LIFTGATE LOCK CYLINDER ble by a latch actuator attached to the leading edge of the power latch assembly. This 12 volt latch actuator contains a small drive gear that meshes with the latch assemblies internal gears to perform the power cinch close / power release operations. Refer to the Latch assembly for more information. The power cinch/release actuator is serviceable component. Consult your Mopar™ parts catalog for specific part numbers. OPERATION During a power close cycle, the power cinch actuator provides the torque required to close the power liftgate from the secondary to the primary closed and latched position. During a power open cycle, the power release actuator releases the liftgate from the primary closed and latched position to the fully unlatched and movable position. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Open the liftgate and remove the lower liftgate trim panel. Refer to Body for the procedure. (3) Disconnect the power latch electrical connector (Fig. 13). (4) Remove the three latch retaining bolts. 8N - 16 POWER LIFTGATE SYSTEM RS LATCH ACTUATOR (Continued) (5) Grab the latch assembly and unhook the key cylinder link rod from the key cylinder (Fig. 13). (6) Place the latch assembly on a bench and locate the three wires leading from the actuator portion of the latch assembly. (7) Disengage the main connector retaining push pins from the latch actuator housing. (8) Back the three wires out of the main latch electrical connector. Refer to the wiring section of the service manual for detailed instructions. (9) Flip the latch assembly over and remove the latch actuator retaining screw(s). (10) Remove the latch actuator from the latch assembly. INSTALLATION (1) Install the latch actuator on the latch assembly. (2) Install the three latch actuator retaining screws. Torque the screws to 4 in. lbs. (3) Install the three wires in the main latch electrical connector. Refer to the wiring section of the service manual for detailed instructions. NOTE: Be certain wires are reinstalled in the correct wire cavities. Failure to do so could result in damage to the latch actuator. Refer to Wiring Diagrams if previous notes were not made. (4) Secure the main connector retaining push pins on the latch actuator housing. (5) Grab the latch assembly and hook the key cylinder link rod on the key cylinder. (6) Position the latch and install the three latch retaining bolts. Torque to 10 N·m (90 in. lbs.). (7) Connect the power latch electrical connector. (8) Install the lower liftgate trim panel. Refer to Body for the procedure. (9) Connect the negative battery cable. EXTERIOR HANDLE SWITCH DESCRIPTION Vehicles equipped with a power liftgate or power locks utilize a exterior handle switch. The exterior handle switch is a electronic release switch mounted to the rear license plate lamp housing assembly, located just above the license plate. This switch controls the power liftgate release function and is also capable of reversing the power liftgate when it is in motion. A full power open cycle cannot be performed using this switch, only one of the power open command switches (key fob and overhead console mounted) can be used to perform a full power open cycle. The exterior handle switch is a serviceable component. Consult your Mopar™ parts catalog for a specific part number. OPERATION When the exterior handle switch is depressed, with the liftgate in the closed position. A message is sent to the Body Control Module (BCM). The Body Control Module then sends a signal to the power liftgate control module via the J1850 PCI data bus circuit. The power liftgate control module then sends a signal to the power latch mounted actuator, which moves the liftgate from the primary closed and latched position to the open and movable position. If the liftgate is not pulled open once the latch releases within a few seconds, the latch will cinch closed again. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Open the liftgate and remove the liftgate trim panel. Refer to the Body section of the service manual for the procedure. (3) Remove the rear lamp bar assembly from the vehicle. Refer to the Body section of the service manual for the procedure. (4) Locate the two wires going to the exterior handle switch. Cut the tie strap and trace the wires to the large electrical connector and back the wires out of the large connector and through the grommet. Refer to the Wiring section of the service manual for detailed instructions. (5) Depress the two exterior handle switch retaining tabs and roll the switch out of the light bar assembly (Fig. 14). INSTALLATION (1) Install the handle switch in the light bar assembly. (2) Locate the two wires going to the exterior handle switch. Install the wires through the grommet and in the large connector. Secure with a tie strap. Refer to the Wiring section of the service manual for detailed instructions. NOTE: Be certain wires are reinstalled in the correct wire cavities. Failure to do so could result in damage to the handle switch. Refer to Wiring Diagrams if previous notes were not made. (3) Install the rear light bar. Refer to the Body section of the service manual for the procedure. (4) Install the liftgate trim panel. Refer to the Body section of the service manual for the procedure. (5) Connect the negative battery cable. POWER LIFTGATE SYSTEM RS 8N - 17 EXTERIOR HANDLE SWITCH (Continued) chime/thermistor assembly is hardwired to the power liftgate module. Second the thermistor provides a outside temperature reading by way of a resistance reading (V - ohms) supplied to the power liftgate module. As temperature increases the resistance reading (V - ohms) increases , as temperature decreases the resistance reading (V - ohms) decreases. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the rear light bar assembly from the vehicle. Refer to Body for the procedure. (3) Using your hands, grasp the light bar at its sides next to thermistor/chime assembly and gently pull the two sides of the light bar apart until the thermistor/chime assembly can be removed. Fig. 14 REAR LIGHT BAR 1 - CHIME / THERMISTOR 2 - ELECTRIC RELEASE HANDLE SWITCH 3 - LICENSE PLATE LAMPS (6) Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes. (7) Verify power liftgate system and handle switch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. INSTALLATION (1) Gently pull the two sides of the light bar apart until the thermistor/chime assembly can be installed. (2) Install the rear light bar assembly on the vehicle. Refer to the Body section of the service manual for the procedure. (3) Connect the negative battery cable. CHIME/THERMISTOR DESCRIPTION Vehicles equipped with a power liftgate utilize a chime/thermistor assembly. The chime/thermistor assembly is a small capacitor shaped electrical component mounted to the rear license plate lamp housing assembly (Fig. 15) , located just above the license plate. The chime portion of the assembly controls the audible chime sound heard at the rear of the vehicle when the power liftgate is in motion. The thermistor portion of the assembly is a temperature sensor, used by the power liftgate module. The chime/thermistor assembly is a serviceable component. Consult your Mopar™ parts catalog for a specific part number. OPERATION The chime/thermistor assembly performs two different functions for the power liftgate system. First, the chime portion provides an audible chime sound which is controlled by the power liftgate module. The Fig. 15 REAR LIGHT BAR 1 - CHIME / THERMISTOR 2 - ELECTRIC RELEASE HANDLE SWITCH 3 - LICENSE PLATE LAMPS 8N - 18 POWER SLIDING DOOR SYSTEM RS POWER SLIDING DOOR SYSTEM TABLE OF CONTENTS page POWER SLIDING DOOR SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - POWER SLIDING DOOR SYSTEM . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE STANDARD PROCEDURE - WELLNUT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - POWER DOOR LEARN CYCLE . . . . . . . . . . . . . . . . . . . . . STANDARD PROCEDURE - SLIDING DOOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . LATCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . SLIDING DOOR MOTOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . FULL OPEN SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . LEFT B-PILLAR SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . 20 . . 21 . . 27 . . 27 . . 27 . . . . . 28 . 28 . 28 . 29 . . . . . 29 . 29 . 29 . 30 . . 30 . . 30 . . . . . 31 . 31 . 31 . 31 POWER SLIDING DOOR SYSTEM DESCRIPTION Some vehicles are equipped with a power opening and closing sliding door system (Fig. 1). Depending on how the vehicle is ordered it may be equipped with only a right side power door or right and left side power doors. This power sliding door system is a complex system consisting of many components. Some of these components are the door motor, latch assembly, sliding door control module, lower drive unit, flex drive assembly, wire harness and track, lower drive unit track and rack assembly, full open switch, B-pillar switch, overhead console switch, key fob switches (Fig. 2), pawl switch, ratchet switch and child lockout and handle switches. page RIGHT B-PILLAR SWITCH DESCRIPTION . . . . . . . . OPERATION . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . LOWER DRIVE UNIT DESCRIPTION . . . . . . . . OPERATION . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . LOWER DRIVE UNIT TRACK DESCRIPTION . . . . . . . . OPERATION . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . WIRING HARNESS DESCRIPTION . . . . . . . . OPERATION . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . FLEX DRIVE DESCRIPTION . . . . . . . . OPERATION . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . SLIDING DOOR MODULE DESCRIPTION . . . . . . . . OPERATION . . . . . . . . . . REMOVAL . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . 31 . 31 . 31 ........ ........ ........ ........ & RACK ........ ........ ........ ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . 31 . 32 . 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . 33 . 33 . 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . 34 . 34 . 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . 36 . 36 . 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . 37 . 38 . 38 Each power side door has its own door control module, located in the center of the door behind the door trim panel. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/DOOR CONTROL MODULE - DESCRIPTION) The power side door motor is located in the front portion of the door, on the inner door panel sheet metal. The latch assembly is located in the rear of the power side door, near the body line. The lower drive unit is attached to the lower door hinge. The flex drive assembly connects the door motor to the lower drive unit. The wire harness and track and the lower drive unit track are visible with the door open in the lower door sill area. The power side door full open switch is located under the lower drive unit and is part of the hold open latch assembly. The pawl, ratchet, handle and child lockout switches are all located on the power side door latch assembly. The B-pillar switch, as it will be POWER SLIDING DOOR SYSTEM RS POWER SLIDING DOOR SYSTEM (Continued) Fig. 1 Power Sliding Door Introduction referred to, is an open and close command switch located on the vehicles interior body side B-pillar trim. The overhead console switch, is an open and close command switch located in the vehicle’s overhead console. More detailed information can be found on these components later in this section. Safety is of the utmost concern with the power sliding door system. Software technology has enabled the power sliding door control module to detect resistance to door travel. This allows the power sliding door to stop and reverse direction any time an obstruction is felt or any of the command switches are operated (while closing only). Battery voltage is supplied to the power sliding door system through a 40 amp fuse, located in the Intelligent Power Module (IPM) assembly (Fig. 3). The child lockout switch prevents children from opening or actuating the power sliding door system when desired. In the unlikely event that the power sliding door system develops a fault, the power sliding door can still be operated manually from the interior or exterior door handle, just like a standard manual sliding door. The power sliding door control module communicates on the J1850 PCI Data Bus Circuit. Therefore, the power sliding door control module can generate and store its own diagnostic trouble codes (DTC). A diagnostic scan tool, such as the DRB IIIt is used to Fig. 2 Key Fob 1 - Left Sliding Door Switch 2 - Right Sliding Door Switch 3 - Liftgate Switch 8N - 19 8N - 20 POWER SLIDING DOOR SYSTEM RS POWER SLIDING DOOR SYSTEM (Continued) Fig. 3 Power Side Door Fuse Location read and diagnose these trouble codes. Refer to the Body Diagnostic Manual for a complete list of diagnostic routines. NOTE: It may be possible to generate Sliding Door Diagnostic Trouble Codes during normal power sliding door operation. Refer to the Body Diagnostic Manual for a complete list of diagnostic routines. For additional information, (Refer to 8 - ELECTRICAL/POWER DOORS - OPERATION). For a complete power sliding door system wiring schematic, refer to Wiring Diagrams. For power sliding door system operation instructions, refer to the vehicle owner manual. WARNING: BE CERTAIN TO READ ALL WARNINGS AND CAUTIONS IN POWER SLIDING DOOR OPERATION BEFORE ATTEMPTING ANY SERVICE OF POWER SLIDING DOOR SYSTEM OR COMPONENTS. OPERATION With the push of a power sliding door open/close command switch (key fob, overhead console or B-pillar mounted) a signal is sent out to the Body Control Module (BCM). The BCM then sends a signal out on the PCI Data Bus circuit (J1850) to the power sliding door module. The power sliding door module then signals the power sliding door latch to release the door to the unlatched and movable position. The motor then starts an open cycle. During the door open cycle, if the power sliding door module detects sufficient resistance to door travel, such as an obstruction in the door’s path, the power sliding door module will immediately stop door movement and reverse door travel to the full open or closed position. The ability for the power sliding door module to detect resistance to door travel is accomplished by hall effect sensors and the door motor speed. The power sliding door control module has the ability to learn. Anytime a door is opened or closed using the power sliding door system the module learns from its cycle. If a replacement power sliding door component is installed or a door adjustment is made, the module must re-learn the effort required to open or close the door. A learn cycle can be performed with a Diagnostic Scan Tool, such as the DRB IIIt, or with a complete cycle of the door, using any one of the command switches. Refer to Standard Procedures in this section for detailed instructions. The power sliding door system is designed with a number of system inhibitors. These inhibitors are necessary for safety and/or feasibility of the power sliding door system. See the power sliding door system inhibitors noted below: POWER SLIDING DOOR SYSTEM INHIBITORS • The power sliding door must be in the full open or closed position in order for the power sliding door system to start a cycle. If the door is not in this position (based on the input from the full open, pawl or ratchet switches) the door control module will not respond to command switch inputs. • The vehicles transmission must be in park or neutral in order for the power sliding door system to start a cycle. • The vehicles child lockout switch must be in the “UNLOCKED” position in order for the power sliding door systems B-pillar switches to function. • If multiple obstacles are detected during the same power open or close cycle the power sliding door may go into full manual mode. • If severe Diagnostic Trouble Codes (DTC) are stored in the power sliding door control module the power sliding door may go into full manual mode. • Due to the high pressure created in the passenger compartment with the blower motor on high, the power sliding door may not complete a power close cycle unless a window is cracked, allowing the pressure to escape. This situation will only be experienced on some vehicles, or vehicles with brand new side door weather seals installed. Refer to the Side Door Adjustment procedure in the Standard Procedures section of this group. • The vehicles fuel tank filler door must be in the closed position. Due to the sliding door interference POWER SLIDING DOOR SYSTEM RS 8N - 21 POWER SLIDING DOOR SYSTEM (Continued) with the open fuel tank filler door, mechanical linkage prevents the side door from opening and striking the fuel door. Refer to the Body section of this manual for detailed information on the fuel door lockout feature. POWER SLIDING DOOR SYSTEM WARNINGS WARNING: ALWAYS DISCONNECT THE NEGATIVE BATTERY CABLE BEFORE ATTEMPTING ANY POWER SLIDING DOOR SYSTEM SERVICE. WARNING: EXTREME CARE MUST BE TAKEN TO PREVENT OBJECTS FROM ENTERING THE DOORS PATH ONCE THE DOOR REACHES THE CINCH MOTOR CONTACT (APPROXIMATELY 1 INCH BEFORE FULLY CLOSED). WARNING: NEVER ATTEMPT TO ENTER OR EXIT THE VEHICLE WHILE THE POWER SLIDING DOOR IS IN MOTION. YOU COULD DAMAGE THE POWER SLIDING DOOR SYSTEM OR COMPONENTS AND/OR CAUSE PERSONAL INJURY. WARNING: NEVER ATTEMPT TO DRIVE AWAY WITH THE POWER SLIDING DOOR IN MOTION. YOU COULD DAMAGE THE POWER SLIDING DOOR SYSTEM OR COMPONENTS AND/OR CAUSE PERSONAL INJURY. WARNING: NEVER PLACE OBJECTS IN THE POWER SLIDING DOOR WHEN CINCHING CLOSED. YOU COULD DAMAGE THE VEHICLE, POWER SLID- ING DOOR SYSTEM OR COMPONENTS AND/OR CAUSE PERSONAL INJURY. DIAGNOSIS AND TESTING - POWER SLIDING DOOR SYSTEM The power opening and closing power sliding door system is a complex system containing many components and modules. In order to obtain conclusive testing, the Programmable Communications Interface (J1850) data bus network and all of the electronic modules that provide inputs to, or receive outputs from the power sliding door system must be checked. The power sliding door system was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB IIIt. The most reliable, efficient, and accurate means to diagnose the power sliding door system requires the use of a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual. The DRB IIIt can be used to observe various switch statuses throughout the power sliding door system to help the technician diagnose a defective switch or component. The DRB IIIt can also be used to actuate various components throughout the power sliding door system to help the technician diagnose a defective component. Before any testing of the power sliding door system is attempted, the battery should be fully charged, all built-in power sliding door system inhibitors read and understood (Refer to 8 - ELECTRICAL/POWER DOORS - OPERATION) and all wire harness and ground connections inspected around the affected areas on the vehicle. The following are quick reference diagnostic tables to help when diagnosing and testing the power sliding door system. 8N - 22 POWER SLIDING DOOR SYSTEM RS POWER SLIDING DOOR SYSTEM (Continued) POWER SLIDING DOOR SYSTEM DIAGNOSIS CONDITION Door opens unexpectedly POSSIBLE CAUSES CORRECTION Failure of sliding door control or body control module Disconnect then reconnect battery to reset module, function door, if no function exists check for loose wire connections, Refer to the Body Diagnostic Manual for detailed procedures Failure of latch assembly Check wiring/cable connections and for blown fuse Check for trouble codes, replace latch if necessary Failure of open/close command switch Check for shorted or defective switch Failure of striker Striker misaligned or loose Striker damaged Replace striker if necessary Door will not open manually using inside handle Failure of inside handle assembly Check for broken inside handle assembly Check cable connections at latch and handle assembly. Check for binds or kinks in cable. Check for foreign matter preventing the operation of handle assembly Replace the handle if necessary Failure of latch assembly Check cable connections Check for foreign matter preventing the operation of latch assembly Replace latch if necessary Failure of inside handle cable assembly Check cable for binding Check cable for broken condition Replace the cable, if necessary Binding or sticking of components Check for foreign matter preventing the operation of door Establish location of binding Replace necessary components Door will not open manually using outside handle Failure of outside handle assembly Check for broken outside handle assembly Check cable connections at latch and handle assembly. Check for binds or kinks in cable. Check for foreign matter preventing the operation of handle assembly POWER SLIDING DOOR SYSTEM RS 8N - 23 POWER SLIDING DOOR SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Replace the handle if necessary Failure of latch assembly Check cable connections Check for foreign matter preventing the operation of latch assembly Replace latch assembly, if necessary Failure of outside handle cable assembly Check cable for binding Check cable for broken condition Replace the cable, if necessary Binding or sticking of components Check for foreign matter preventing the operation of door Establish location of binding Replace necessary components Sliding door will not open/close manually Binding or sticking of components Establish location of binding. Disconnect flex drive and recheck. Replace necessary components Failure of latch assembly Check cable connections Check for foreign matter preventing the operation of latch assembly Replace latch assembly, if necessary Sliding door will not open/close under power Failure of sliding door control or body control module Disconnect then reconnect battery to reset module, function door, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of latch assembly Check wire connections and for blown fuse Check cable connections Check for foreign matter preventing the operation of latch assembly Troubleshoot using body diagnostic manual Replace latch assembly, if necessary Power loss during power door operation Failure of motor assembly Troubleshoot using body diagnostic manual Failure of full open switch assembly Troubleshoot using body diagnostic manual Failure of flex drive assembly Disconnect flex drive and check for broken condition Failure of lower drive unit assembly Remove lower drive unit and check for broken condition Binding or sticking of components Establish location of binding and replace necessary components Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams 8N - 24 POWER SLIDING DOOR SYSTEM RS POWER SLIDING DOOR SYSTEM (Continued) CONDITION No latching in primary and/or secondary positions POSSIBLE CAUSES CORRECTION Low battery voltage Charge battery Failure of sliding door control or body control module Disconnect then reconnect battery to reset module, function door, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of drive assembly Remove lower drive unit and check for no drive condition Failure of inside/outside handle assembly Go to that 9POSSIBLE CAUSE9 and review 9CORRECTIONS9 Failure of latch assembly Check wire connections and for blown fuse Check cable connections Check for foreign matter preventing the operation of latch assembly Troubleshoot using body diagnostic manual Replace latch assembly, if necessary Binding or sticking of components Establish location of binding and replace necessary components Failure of sliding door control or body control module Disconnect then reconnect battery to reset module, function door, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Door seal force too high Inspect seals for damage, mis-assembly, foreign matter. Refer to Door adjustment in the Body section of the service manual for specifications Failure of drive assembly Remove lower drive unit and check for no drive condition Failure of striker Striker misaligned or loose Striker damaged Replace striker if necessary Latch will not fully release from primary position Failure of latch assembly Check wire connections and for blown fuse Check cable connections Check for foreign matter preventing the operation of latch assembly Troubleshoot using body diagnostic manual Replace latch assembly, if necessary Failure of fuel filler door lockout mechanism Check operation of fuel filler door lockout mechanism. Refer to the Body section for information Failure of sliding door control or body control module Disconnect then reconnect battery to reset module, function door, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of striker Striker misaligned or loose POWER SLIDING DOOR SYSTEM RS 8N - 25 POWER SLIDING DOOR SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Striker damaged Replace striker if necessary Key fob, B-pillar or overhead console switch does not power operate door Cables worn and stretched Replace cables as necessary Binding or sticking of components Establish location of binding and replace necessary components Blown Fuse Check fuse and replace Battery voltage low Charge or replace battery Failure of latch assembly Check for foreign matter preventing the operation of latch assembly Check wire connection Pawl and/or ratchet switch inoperative Replace latch if necessary Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Failure of body control module Check electrical connections Refer to the body diagnostic manual for additional checks Replace BCM if necessary Failure of key fob Replace key fob battery Replace key fob if necessary Failure of sliding door control module Disconnect then reconnect battery to reset module, function door, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of door motor assembly Check for foreign matter preventing the operation of gear motor assembly Check wire connections Gear motor clutch does not engage, replace assembly Full open switch inoperative, replace hold open latch assembly Replace motor assembly. if necessary Door does not stay open Failure of hold open latch assembly Check wire/cable connections Replace hold open latch, if necessary High inside/outside opening effort Failure of hold open latch striker Replace hold open latch striker, if necessary Failure of latch assembly Check wire connections and for blown fuse Check cable connections 8N - 26 POWER SLIDING DOOR SYSTEM RS POWER SLIDING DOOR SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Check for foreign matter preventing the operation of latch assembly Troubleshoot using body diagnostic manual Replace latch assembly, if necessary Door continues to cinch closed during power mode Failure of inside/outside handle assembly Go to that 9POSSIBLE CAUSE9 and review 9CORRECTIONS9 Binding or sticking of components Establish location of binding and replace necessary components Failure of latch assembly Check wire connections and for blown fuse Check for foreign matter preventing the operation of latch assembly Troubleshoot using body diagnostic manual Replace latch assembly, if necessary Door continues to open during power mode (runaway motor) Failure of sliding door control or body control module Disconnect then reconnect battery to reset module, function door, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Failure of sliding door control or body control module Disconnect then reconnect battery to reset module, function door, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of hold open latch assembly Check wire/cable connections Replace hold open latch, if necessary Door opens very slowly Failure of drive assembly Remove lower drive unit and check for no drive condition Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Failure of door motor assembly Check wire/cable connections Replace motor assembly, if necessary Squeaks, Noises and rattles Binding or sticking of components Establish location of binding and replace necessary components Foreign material in door compartment Remove foreign material Loose components Check and tighten loose components Poor door track lubrication Lubricate the front portions of the side door tracks with 9Door EaseT9 or equivalent POWER SLIDING DOOR SYSTEM RS 8N - 27 POWER SLIDING DOOR SYSTEM (Continued) STANDARD PROCEDURE STANDARD PROCEDURE - WELLNUT REPLACEMENT Vehicles equipped with a power sliding door utilize wellnuts. These wellnuts are used to hold and isolate the power sliding door motor to and from the door inner panel. The wellnut functions like a expandable rubber core plug, as the screw fastener is threaded into the wellnut and tightened the wellnuts diameter increases. This secures the door motor assembly to the inner panel and keeps the audible motor vibrations to a minimum. If a wellnut shows signs of wear, it must be replaced. Follow the procedure below if replacement is necessary. (1) Remove the door motor from the door inner panel. (Refer to 8 - ELECTRICAL/POWER DOORS/ MOTOR - REMOVAL). (2) Remove the wellnuts from the inner panel by pulling them straight out (Fig. 4). If a wellnut is difficult to remove, use a high leverage cutting tool to cut the wellnut in half and remove the two halves from the door assembly. CAUTION: Be certain to use the correct torque specification (35 in.lbs.) when installing the door motor retaining screws. STANDARD PROCEDURE - POWER DOOR LEARN CYCLE Any time a power side door component is removed, replaced, door adjustment is performed or diagnostic trouble codes are addressed and erased, a learn cycle must be performed. This learn cycle enables the power side door control module to learn or relearn its critical information (travel limits, resistance to door travel, etc.) which allows it to perform properly and safely. It also tells the technician that the system is performing properly and is able to be returned to service. To perform a power door learn cycle do the following: (1) Obtain a DRB IIIt scan tool. Connect the DRB IIIt to the vehicle and check for any power side door system stored diagnostic trouble codes, erase any stored codes. Operate the system and check to see if any trouble codes return. If any diagnostic trouble codes return, diagnose, correct and erase the codes before performing the learn cycle. If a DRB IIIt scan tool is not available, the learn cycle can be performed by opening and closing the power side door using any of the normal open/close command switches. Be certain to cycle the side door through a complete open and close cycle or the procedure will not be complete. (2) Using the DRB IIIt, Go into Test Routine Menu and select a power open command. (3) Select a power close command. (4) The power side door learn cycle is complete. NOTE: If the power side door will not complete a full cycle, a problem exists with the power side door system. Refer to Power Side Door Diagnosis and Testing. STANDARD PROCEDURE - SLIDING DOOR ADJUSTMENT Fig. 4 Side Door Motor Wellnuts 1 - Wellnuts 2 - Side Door Inner Panel (3) Install the replacement wellnuts in the inner panel and install the door motor(Refer to 8 - ELECTRICAL/POWER DOORS/MOTOR - INSTALLATION) . In order for the power sliding door system to function properly the door must move freely and smoothly. The power sliding door system can accommodate for some minor changes in the effort required to move the door. However, in extreme conditions the door may need to be mechanically adjusted for proper fit. (Refer to 23 - BODY/DOORS - SLIDING/SLIDING DOOR - ADJUSTMENTS). If a problem exists with the power sliding door and it is suspected to be extreme effort, check for proper door alignment and adjustment first, then check the door tracks and drive unit for free manual operation. 8N - 28 POWER SLIDING DOOR SYSTEM RS POWER SLIDING DOOR SYSTEM (Continued) Use a known good vehicle for side door comparison data. Refer to the Side Door Adjustment procedure in the Body section of the service manual for detailed instructions. LATCH DESCRIPTION OPERATION The power latch performs the same operation as a full manual door latch as well as power cinch, release, lock and unlock operations. The power latch mounted actuator cinches the door closed and latches it in its primary latched position. During a power close cycle, the power cinch actuator will not operate until the side door has reached its secondary latch position (determined by pawl and ratchet switches). During a power open cycle, the power release actuator will stop once the side door has moved from primary latch position. The power latch uses inputs from the lock/unlock actuator, power side door control module and child lockout, pawl, ratchet and handle switches to provide safe power cinch and release operations. Refer to Power Side Door Operation for additional information. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the appropriate side door trim panel. Refer to the Body section for the procedure. (3) Remove the weather shield if necessary. Refer to the Body section for the procedure. (4) Open the side door all the way and remove the door latch retaining bolts (Fig. 6). Fig. 5 Removing/Installing Power Latch in Sliding Door 1 - Power Latch Assembly Vehicles equipped with a power side door or doors utilize a power latch. One power latch is used for each power door. The latch is located on the trailing edge of the side door assembly (Fig. 5). This power latch assembly is comprised of many different components which have the ability to perform the power cinch, release, lock, unlock and safety related operations. These components are the door latch, lock/unlock actuator, cinch/release actuator and child lockout, pawl, ratchet and handle switches. The pawl and ratchet switches are used to indicate the primary and secondary latched positions. The cinch latch also provides a connection point for the interior handle, exterior handle and hold open latch cables. The power latch is a replaceable component. Consult your Mopar parts catalog for specific part numbers. Fig. 6 Removing Latch Retaining Bolts 1 - Latch Retaining Bolts 2 - Side Door POWER SLIDING DOOR SYSTEM RS 8N - 29 LATCH (Continued) (5) Partially close the door and pull the latch assembly out of the side door inner panel. (6) Disconnect all electrical connectors leading to the latch assembly. (7) Disconnect the inside and outside handle cables from the latch assembly. Refer to the Body Section of the service manual for the procedure. (8) Disconnect the hold open latch cable from the latch assembly. Refer to the Body Section of the service manual for the procedure. (9) Disconnect lock actuator link rod from the latch assembly. (10) Remove the latch assembly from the vehicle. INSTALLATION (1) Position the latch assembly in the vehicle. Be certain all latch mounted components are installed on the replacement latch assembly. If not, transfer components from the old latch to the new latch assembly. (2) Connect the lock actuator link rod on the latch assembly. (3) Connect the hold open latch cable on the latch assembly. Refer to the procedure in this section for detailed instructions. (4) Connect the inside and outside handle cables on the latch assembly. Refer to the procedure in the Body section for detailed instructions. (5) Connect all electrical connectors leading to the latch assembly. (6) With assistance from another person, position the side door and install the door latch retaining bolts. Torque to 10 - 12 N·m (100 in. lbs.). (7) Install the weathershield if necessary. Refer to the procedure in the Body section for detailed instructions. (8) Install the appropriate side door trim panel. Refer to the procedure in the Body section for detailed instructions. (9) Connect the negative battery cable. SLIDING DOOR MOTOR DESCRIPTION Vehicles equipped with a power sliding door utilize a door motor assembly. The door motor is located in the center of the side door (Fig. 7) and is comprised of three parts. The three parts of the door motor assembly are the motor, gear reduction and clutch assembly. The door motor assembly provides the power and torque to move the sliding door from the open/closed position to full closed/open position, after the power latching mechanism has released. Special wellnuts and screws are used in the side door inner panel to retain the door motor to the door Fig. 7 Side Door Components 1 2 3 4 5 6 7 - Sliding Door Control Module Module Retaining Screw Module Electrical Connectors Door Motor Assembly Flex Drive Assembly Door Motor Retaining Fasteners Door Motor Electrical Connector panel. Refer to Standard Procedures in this section for additional wellnut information. The door motor is replaced as a complete assembly, which includes the DC motor, gear reduction and clutch assemblies. Consult your Mopar parts catalog for specific part numbers. OPERATION With the push of a Power Side Door (PSD) command switch, the PSD control module will signal the latch assembly to release the door from its primary locked position. The drive motor will then take over to provide the power to open the door to its full open or closed position. The gear reduction portion of the motor assembly reduces the speed of the motor from 5800 to 260 rpm and also increases the torque to the lower drive unit. The clutch portion of the motor assembly engages the motor to drive the door under power and disengages it so the door can be moved easily under manual operation. REMOVAL (1) Disconnect and isolate the negative battery cable. 8N - 30 POWER SLIDING DOOR SYSTEM RS SLIDING DOOR MOTOR (Continued) (2) Remove the door trim panel from the appropriate side door. Refer to the Body section for the procedure. (3) Remove water shield as necessary to gain access to motor assembly. (4) Remove retaining clip holding flex drive assembly to the motor (Fig. 8). Pull flex drive cable straight out of the motor assembly. FULL OPEN SWITCH DESCRIPTION Fig. 9 Full Open Switch Position & Orientation 1 - Hold Open Latch Assembly 2 - Hold Open Latch Cable 3 - Full Open Switch Fig. 8 Flex Drive Retaining Clip 1 - Flex Drive Cable Retaining Clip 2 - Flex Drive Cable 3 - Side Door Motor Assembly (5) Disconnect door motor electrical connector. (6) Remove the 4 screws holding the motor to the inner door panel. (7) Remove the motor assembly from the vehicle. INSTALLATION (1) Position the motor assembly on the door inner panel. (2) Install the 4 screws holding the motor to the inner door panel. Torque to 35 in. lbs. (3) Install the flex shaft by lining up the square shaped drive shaft with corresponding hole in motor drive unit and push straight in. (4) Install the E-clip to secure flex-shaft. (5) Connect the negative battery cable. (6) Install the weather shield. Refer to the Body section of the service manual for the procedure. (7) Install the door trim panel on the side door. Refer to Body for the procedure. Vehicles equipped with a power sliding door utilize a full open switch. This switch is located in the hold open latch (Fig. 9) under the side door lower hinge. When the power side door module receives a ground signal input from the full open switch, and as long as the cinching latch actuator is not in power mode or the handle switch is open, the signal indicates that the door is at the full open position. The full open switch is incorporated into the hold open latch. If the full open switch proves faulty, the entire hold open latch assembly must be replaced. OPERATION The full open switch is triggered by a pawl lever in the hold open latch. When the full open switch is closed (circuit to ground) the ratchet has engaged on the hold open striker and the pawl lever has engaged on the ratchet, locking the latch from opening and holding the door in the full open position. RS LEFT B-PILLAR SWITCH DESCRIPTION Vehicles equipped with power sliding side door/s utilize B-pillar switches. These switches are located on the interior of the vehicle, on the B-pillar trim panels. These switches serve as an open and close command switch for the appropriate power side door. The B-pillar switches are replaceable. Consult your Mopar parts catalog for a specific part number. OPERATION When the Pillar switch is depressed a signal is sent to the Body Control Module (BCM), this signal is then sent to the Power Sliding Door Module, telling it to start a power open or close cycle. The child lockout feature must be disabled and the side door must be unlocked in order for the Pillar switch to function. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Using a trim stick or other small flat-bladed pry tool, gently pry the leading upper edge of the B-pillar switch away from the B-pillar trim. (3) Once the upper edge is free from pillar trim, rock the switch out of the switch opening. (4) Disconnect the B-pillar switch electrical connector. First, slide the connector lock away from the switch then, depress connector retaining tab while pulling straight apart. (5) Remove the B-pillar switch from the vehicle. INSTALLATION (1) Connect the B-pillar switch electrical connector. Slide connector lock toward the switch to lock in place. (2) Hook the lower edge of the B-pillar switch on the B-pillar trim and then push the switch firmly into position. (3) Connect the negative battery cable. RIGHT B-PILLAR SWITCH DESCRIPTION Vehicles equipped with power sliding side door/s utilize B-pillar switches. These switches are located on the interior of the vehicle, on the B-pillar trim panels. These switches serve as an open and close command switch for the appropriate power side door. The B-pillar switches are replaceable. Consult your Mopar parts catalog for a specific part number. POWER SLIDING DOOR SYSTEM 8N - 31 OPERATION When the Pillar switch is depressed a signal is sent to the Body Control Module (BCM), this signal is then sent to the Power Sliding Door Module, telling it to start a power open or close cycle. The child lockout feature must be disabled and the side door must be unlocked in order for the Pillar switch to function. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Using a trim stick or other small flat-bladed pry tool, gently pry the leading upper edge of the B-pillar switch away from the B-pillar trim. (3) Once the upper edge is free from pillar trim, rock the switch out of the switch opening. (4) Disconnect the B-pillar switch electrical connector. First, slide the connector lock away from the switch then, depress connector retaining tab while pulling straight apart. (5) Remove the B-pillar switch from the vehicle. INSTALLATION (1) Connect the B-pillar switch electrical connector. Slide connector lock toward the switch to lock in place. (2) Hook the lower edge of the B-pillar switch on the B-pillar trim and then push the switch firmly into position. (3) Connect the negative battery cable. LOWER DRIVE UNIT DESCRIPTION Vehicles equipped with a power sliding side door utilize a lower drive unit. The lower drive unit is located on the sliding door lower hinge assembly (Fig. 10). This drive unit is used to transfer the lateral rotation of the flex drive assembly into longitudinal movement via the drive unit gear and door track rack teeth (Fig. 10). The lower drive unit is a replaceable component. Consult your Mopar parts catalog for specific part numbers. OPERATION During a power open or close cycle, the power drive unit is driven by the flex drive assembly. The lower drive units main gear engages the lower door tracks rack teeth, this moves the side door assembly accordingly. 8N - 32 POWER SLIDING DOOR SYSTEM RS LOWER DRIVE UNIT (Continued) Fig. 10 Lower Drive Unit 1 - Lower Drive Unit 2 - Flex Drive Assembly REMOVAL Fig. 11 Sliding Door Lower Hinge Assembly 1 2 3 4 - Lower Drive Unit Cover Lower Drive Unit Cover Retaining Screws Sliding Door Lower Hinge Arm Bracket (1) Disconnect and isolate the negative battery cable. (2) Open the appropriate side door and remove the lower drive unit cover retaining screws (Fig. 11). (3) Remove the lower drive unit retaining fasteners (Fig. 12). (4) Disconnect the flex drive assembly from the lower drive unit. Expand the flex drive collar until the lower drive unit can be pulled straight off. (5) Remove the lower drive unit from the vehicle. INSTALLATION (1) Position the lower drive unit near the lower hinge. (2) Connect the flex drive assembly on the lower drive unit. Push the flex drive collar straight on until the it snaps in place (Fig. 12). (3) Install the lower drive unit retaining fasteners (Fig. 12). Torque the larger allen headed center stud to 9 N·m (80 in. lbs.). Torque the smaller screw to 3 N·m (28 in. lbs.). (4) Install the lower drive unit cover and retaining screws (Fig. 11). (5) Connect the negative battery cable. Fig. 12 Lower Drive Unit Retaining Fasteners 1 - Lower Drive Unit Retaining Screw 2 - Do Not Remove 3 - Lower Drive Unit Retaining Bolt POWER SLIDING DOOR SYSTEM RS LOWER DRIVE UNIT TRACK & RACK DESCRIPTION 8N - 33 REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the side door sill plate from the lower of the door opening. Refer to the Body section for the procedure. (3) Remove the hold-open striker. Refer to Body for the procedure. (4) Position a floor jack, with a block of wood under the leading edge of the side door to support it (Fig. 14). Fig. 13 Rack Access Hole Locations 1 2 3 4 - Lower Door Track and Rack Assembly Wire Harness Rack Access Hole Sealing Patches Lower Drive Unit Cover Vehicles equipped with a power sliding side door utilize a lower drive unit track or door track and rack assembly. This track provides a mating rack gear (Fig. 13) for the lower drive unit to engage. The track also accepts the lower hinge rollers, which helps support the weight of the side door as well as providing a smooth surface for the hinge rollers to move upon. The lower door track is a replaceable component. Consult your Mopar parts catalog for specific part numbers. OPERATION With the start of a power door open cycle, the door motor drives the flex drive assembly. The flex drive assembly drives the lower drive unit. A metal drive gear which is part of the lower drive unit, meshes with the door track rack teeth and moves the door into the full open position. The same operation repeats itself, during a power close cycle only the system rotates in the opposite direction. Fig. 14 Supporting Side Door (5) Remove the lower hinge assembly from the door. Refer to the Body section of the service manual for the procedure. (6) Position the wire harness assembly out of door opening (Fig. 13), this will allow sufficient room to remove the door track. (7) Pull back the sealing patches (Fig. 13) and remove the lower track retaining nuts (Fig. 15). (8) Carefully remove the lower door track from the vehicle. INSTALLATION (1) Carefully position the lower door track in the vehicle. (2) Install the lower track retaining nuts (Fig. 15) and install the sealing patches. Torque the fasteners to 70 in. lbs. (3) Install the lower hinge assembly on the door. Refer to the Body section of the service manual for the procedure. 8N - 34 POWER SLIDING DOOR SYSTEM RS LOWER DRIVE UNIT TRACK & RACK (Continued) Fig. 15 Lower Track Retaining Bolts 1 - Lower Track Retaining Bolts 2 - Lower Door Track NOTE: Take care to locate the lower hinge assembly on the door in its original position (ie. match screw washer with rings left on hinge). Adjust door fit if required. (4) Remove the floor jack (Fig. 14). (5) Install the hold-open striker. Refer to the Body section for the procedure. (6) Install the side door sill plate on the lower of the door opening. Refer to the Body section for the procedure. (7) Connect the negative battery cable. WIRING HARNESS DESCRIPTION The wire harness supplies power (12v), ground and various electrical signals to the side sliding door for various power door functions. A plastic chain or wiring track covers the wire harness assembly (Fig. 16) and is used to protect the wire harness from abrasion and/or tangling. This wiring track is replaced with the wire harness assembly. The wire harness assembly is a replaceable component. Consult your Mopar parts catalog for specific part numbers. Fig. 16 Wire Harness Position and Orientation 1 2 3 4 - Lower Door Track and Rack Assembly Wire Harness Rack Access Hole Sealing Patches Lower Drive Unit Cover OPERATION The wire harness and plastic wiring track provide a safe and reliable means of supplying power, ground and other various electrical connections to the side sliding door. During sliding door movement the wiring track folds and unfolds like the links in a chain. REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the appropriate door trim panel from the sliding side door. Refer to the Body section for the procedure. (3) Remove the lower drive unit cover retaining screws and remove the cover (Fig. 17). (4) Disconnect the power side door electrical connector, located just behind the lower drive unit assembly. (5) Disengage retaining pushpin and pull wire harness away from its power side door mounting location (Fig. 16). (6) Using a flat bladed screwdriver, unsnap the wire harness retaining clip from the lower drive unit. (7) Slide the wire harness off the forward lower drive unit stud. (8) Using a pushpin removal tool, unsnap wire harness retaining pushpins from the rocker panel. POWER SLIDING DOOR SYSTEM RS 8N - 35 WIRING HARNESS (Continued) (9) Install the appropriate door trim panel on the sliding side door. Refer to the Body section for the procedure. (10) Connect the negative battery cable. FLEX DRIVE DESCRIPTION Fig. 17 Lower Hinge/Drive Assembly 1 2 3 4 - Lower Drive Unit Cover Lower Drive Unit Cover Retaining Screws Sliding Door Lower Hinge Arm Bracket (9) Remove side door lower sill plate. Refer to Body for the procedure. (10) Pull back the rearward edge of the B-pillar trim to access the wire harness connector and disconnect connector. (11) Remove the wire harness assembly from the vehicle. INSTALLATION (1) Position the wire harness assembly in the vehicle. (2) Connect the wire harness connector located at the rearward edge of the B-pillar. (3) Install the side door lower sill plate. Refer to the Body section for the procedure. (4) Snap the wire harness retaining pushpins in the rocker panel. (5) Slide the wire harness on the lower drive unit stud. (6) Install the wire harness retaining clip on the lower drive unit stud. (7) Connect the power side door electrical connector, located just behind the lower drive unit. (8) Install the lower drive unit cover and retaining screws. Fig. 18 Side Door Components 1 2 3 4 5 6 7 - Sliding Door Control Module Module Retaining Screw Module Electrical Connectors Door Motor Assembly Flex Drive Assembly Door Motor Retaining Fasteners Door Motor Electrical Connector Vehicles equipped with a power sliding side door utilize a flex drive assembly. The flex drive assembly is located in the lower portion of the door (Fig. 18) and is used to connect the door motor to the lower drive unit. An E-clip is used to secure the flexdrive to the motor assembly, while the flex drive collar is used to secure the drive to the lower drive unit. The flex drive assembly is basically a flexible drive shaft for the power side door system. The flex drive assembly is a replaceable component. Consult your Mopar parts catalog for specific part numbers. 8N - 36 POWER SLIDING DOOR SYSTEM RS FLEX DRIVE (Continued) OPERATION With one end of the flex drive attached to the door motor and the other attached to the lower drive unit, the flex drive transfers the power and torque from the motor to the drive unit. A square shaped drive cable, inside the flex drive assembly engages the motor drive and rotates to move the door accordingly. REMOVAL (1) Disconnect and isolate the negative cable. (2) Remove the side door trim panel from the vehicle. Refer to the Body section for the procedure. (3) Remove the weathershield. Refer to the Body section for the procedure. (4) Remove the E-clip from the flex drive assembly (Fig. 19). Fig. 20 Lower Hinge/Drive Assembly 1 2 3 4 - Lower Drive Unit Cover Lower Drive Unit Cover Retaining Screws Sliding Door Lower Hinge Arm Bracket INSTALLATION Fig. 19 Flex Drive E-Clip 1 - Flex Drive Cable Retaining Clip 2 - Flex Drive Cable 3 - Side Door Motor Assembly (5) Pull the flex drive straight out of the motor assembly. (6) Remove the lower drive unit cover retaining screws and remove the cover (Fig. 20). (7) Expand the flex drive collar, next to the lower drive unit until the flex drive can be pulled straight off the lower drive unit. (8) Remove the flex drive assembly from the vehicle. (1) Position the flex drive assembly in the vehicle. (2) Install the flex drive on the lower drive unit. Push straight on until it snaps in place. It may be necessary to rotate drive unit gear slightly until the flex drive seats in place. (3) Install the lower drive unit cover and retaining screws. (4) Install the flex drive in the motor assembly. Line up the square shaped inner shaft and push straight on (Fig. 21). (5) Install the E-clip on the flex drive assembly (Fig. 19). (6) Install the weathershield. Refer to Body for the procedure. (7) Install the side door trim panel on the vehicle. Refer to Body for the procedure. (8) Connect the negative cable. POWER SLIDING DOOR SYSTEM RS 8N - 37 FLEX DRIVE (Continued) Fig. 21 Flex Drive Cable 1 - Door Motor 2 - Flex Drive Collar 3 - Flex Drive Inner Shaft SLIDING DOOR MODULE DESCRIPTION Vehicles equipped with a power sliding door utilize a sliding door control module. The sliding door control module is located behind the sliding door trim panel in the center of the door, just above the sliding door motor (Fig. 22). This module controls the operation of the door through the Programmable Communication Interface (PCI) J1850 data bus circuit and the Body Control Module. The sliding door control module contains software technology which enables it to detect resistance to door travel and to reverse door travel in order to avoid damage to the door or to avoid possible personal injury if the obstruction is a person. This feature functions in both the opening and closing cycles. If the power sliding door system develops any problems the control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB IIIt is required to read and troubleshoot these trouble codes. The sliding door control module can be reflashed if necessary. Refer to the latest Technical Service Bulletin (TSB) Information for any updates. The power door control module is a replaceable component and cannot be repaired, if found to be faulty it must be replaced. Consult your Mopar™ parts catalog for a specific part number. Fig. 22 Side Door Components 1 2 3 4 5 6 7 - Sliding Door Control Module Module Retaining Screw Module Electrical Connectors Door Motor Assembly Flex Drive Assembly Door Motor Retaining Fasteners Door Motor Electrical Connector OPERATION The power sliding door control module serves as the main computer for the power sliding side door system. All power door functions are processed through the power door control module and/or the vehicles body control module (BCM). At the start of a power open command, a signal is sent to the BCM and then to the power door control module via the J1850 data bus circuit. This signal, generated by any of the power door command switches, tells the power door control module to activate a power latch release, engage the clutch assembly and drive the door into the full open position. If an obstacle is felt during this power open cycle, the module will reverse direction and close the door. This process is also enabled during a power close cycle. This process will repeat three times, and if a fourth obstacle is detected, the door will go into full manual mode. Once the full open position is obtained, a hold open latch assembly mounted full open switch tells the control module that the door has reached the full open position. If the power sliding door system develops any problems the control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB IIIt is required to read and troubleshoot these trouble codes. 8N - 38 POWER SLIDING DOOR SYSTEM RS SLIDING DOOR MODULE (Continued) REMOVAL INSTALLATION (1) Disconnect and isolate the negative battery cable. (2) Remove the appropriate door trim panel from the vehicle. Refer to Body for the procedure. (3) Remove the weather shield. Refer to Body for the procedure. (4) Disconnect the power door control module electrical connectors. Slide the red locking tab out (away from module) and depress connector retaining tab, while pulling straight apart. (5) Remove the control module retaining screw (Fig. 22). (6) Remove the module from the vehicle. (1) Position the control module and install the retaining screw. (2) Connect the control module electrical connectors. Slide the locking tab into the locked position. (3) Install the appropriate door trim panel on the vehicle. Refer to Body for the procedure. (4) Install the weather shield. Refer to Body for the procedure. (5) Connect the negative battery cable. (6) Using an appropriate scan tool, check and erase any power door control module diagnostic trouble codes. (7) Verify power door system operation. Cycle the power door through one complete open and close cycle. POWER LOCKS RS 8N - 39 POWER LOCKS TABLE OF CONTENTS page POWER LOCKS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DOOR CYLINDER LOCK SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - DOOR CYLINDER LOCK SWITCH ........... REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . DOOR LOCK MOTOR DIAGNOSIS AND TESTING - DOOR LOCK MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR LOCK SWITCH DIAGNOSIS AND TESTING - DOOR LOCK SWITCH ......................... REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . KEYLESS ENTRY TRANSMITTER STANDARD PROCEDURE STANDARD PROCEDURE - HORN CHIRP PREFERENCE . . . . . . . . . . . . . . . . . . . . . . . . 39 . . . 40 . . . 41 . . . 41 . . . 41 . . . 42 . . . 42 . . . 42 . . . 42 . . . 43 . . . 43 page STANDARD PROCEDURE - BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY ........................ REMOTE KEYLESS ENTRY MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE . . . . . . . . . . . STANDARD PROCEDURE - PROGRAMMING RKE MODULE . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . SLIDING DOOR LOCK MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43 . . . 43 . . . 43 . . . 44 . . . 44 . . . 44 . . . 44 . . . 44 . . . 45 . . . 45 . . . 45 . . . 43 POWER LOCKS DESCRIPTION POWER DOOR LOCK SYSTEM The front doors, sliding door(s) and liftgate are equipped with actuator motors to lock or unlock the latch mechanisms. The door lock actuator motor is not serviced separately from the door latch, except for the sliding door(s). AUTOMATIC DOOR LOCK The vehicle comes with two options for power door locks: • Rolling automatic lock (ENABLE), doors automatically lock at approximately at 25.7 Km/h (16 mph). • No rolling automatic lock (DISABLE), doors do not automatically lock when the vehicle is moving. AUTOMATIC DOOR UNLOCK The doors will unlock automatically on vehicles equipped with power door locks if: • Auto door locks feature is enabled and automatic unlock is enabled. • The transmission was in gear and speed is above zero. • The transmission in park or neutral and speed is zero. • Any door (excluding liftgate) opens. DOOR LOCK INHIBIT The BCM cancels out the door lock switch actuation, when the key is in the Ignition Switch and either front door is open. Pressing the key fob RKE lock/unlock under these conditions results in normal lock/unlock activation. CENTRAL LOCKING If equipped with Vehicle Theft Security System (VTSS), all the doors can be locked with the key by using any of the door lock cylinders. Turning the key to the lock position will lock all the doors. DOOR LOCK CIRCUIT PROTECTION The door lock system is protected by a 40 amp fuse located in the IPM. The BCM receives lock/unlock input and will turn on the appropriate drivers and provide a voltage level to the door lock motor for a specific time. The IPM is located along the side of the vehicle battery in the engine compartment. 8N - 40 POWER LOCKS RS POWER LOCKS (Continued) REMOTE KEYLESS ENTRY SYSTEM AUTOMATIC DOOR LOCKS The BCM is equipped with a disable feature to stop the speed sensitive automatic door locks from functioning. The DISABLE feature can be switched ON or OFF as desired. When the system is DISABLED the door locks will operate normally, but will not lock automatically when the vehicle is rolling. When the door locks are ENABLED the door locks will automatically lock when the vehicle is moving at about 25.7 Km/h (16 mph). All doors are closed, the PCM has set the “OK TO LOCK” bit, and doors were not previously locked. DOOR LOCK INHIBIT Fig. 1 KEY FOB 1 - LEFT SLIDING DOOR BUTTON 2 - RIGHT SLIDING DOOR BUTTON 3 - LIFTGATE SWITCH The key fob transmitter (Fig. 1) has six buttons. Three of them, LOCK, UNLOCK, and PANIC, are used to actuate parts of, and program the Remote Keyless Entry (RKE) system via the customer programming mode. It is not necessary to use the PANIC button with the DRB IIIt scan tool mode of programming. OPERATION POWER DOOR LOCK SYSTEM The Body Control Module (BCM) locks or unlocks the doors when an actuation input signal from a door lock switch or Remote Keyless Entry Module (RKE) is received. The BCM turns on the output drivers and provides a voltage level to the door lock motor for a specified time. The BCM locks the doors automatically when the vehicle is driven beyond the speed of 25.7 Km/h (16 mph). The rolling door lock feature can be disabled if desired. All doors and liftgate can be locked or unlocked using mechanical button or key cylinder methods (Liftgate cylinder does not lock/unlock vehicle. It only unlocks the liftgate). If the key is in the ignition, in any position, and either front door is ajar, all power door lock functioning shall be disabled when activating either door lock switch. Also, if the Vehicle Theft Alarm (VTA) is armed, the door lock switch “UNLOCK” feature will be disabled until the vehicle is disarmed. Pressing the RKE lock/unlock button under these conditions will result in a normal lock/unlock activation. After the key is removed from the Ignition Switch, or the doors are closed, the power door locks will operate normally. CENTRAL LOCKING If equipped with Vehicle Theft Security System (VTSS), all the doors can be locked with the key by using any of the door lock cylinders. Turning the key to the LOCK position will lock all the doors. When either of the front key cylinder switches is detected active, the BCM will activate the illuminated entry feature and the individual front doors will become mechanically unlocked. To central unlock all doors, a second transition from OFF to UNLOCK has to occur within 2 seconds of the first complete UNLOCK cycle. To central unlock the driver door, turn the key to the rear of the vehicle. This indicates an unlock signal to the BCM. For the passenger door, turn the key toward the front of the vehicle. When either key cylinder switch is detected as active, the BCM will activate the illuminated entry feature. The individual doors will become mechanically unlocked. To central lock the vehicle, the driver door lock cylinder is turned toward the front of the vehicle. The passenger door lock cylinder is turned toward the rear of the vehicle. When a lock input from either key cylinder is detected as active, the BCM will cancel the illuminated entry feature and perform the central lock operation. POWER LOCKS RS 8N - 41 POWER LOCKS (Continued) DOOR LOCK CIRCUIT PROTECTION The BCM controls the door lock output drivers. If the door lock switch is actuated continuously for more than one second the BCM will turn the output driver OFF (the BCM would consider the switch stuck). The lock motors are protected with Positive Temperature Coefficient (PTC) device that prevents motor burn out. REMOTE KEYLESS ENTRY SYSTEM • LOCK: Pressing the LOCK button locks all doors and sounds horn (chirp) and arm the Vehicle Theft Security System, if equipped. The chirp verifies that the RKE receiver has sent a message to the BCM for door lock operation. If a door has not been closed before pressing the LOCK button, the vehicle may not be secured and the VTSS will not arm until the door is closed. • UNLOCK: Pressing the UNLOCK button once will unlock the driver’s side doors and activate the illuminated entry system and disarm Vehicle Theft Security System, if equipped. Pressing the UNLOCK button twice within five seconds will unlock all doors and activate the illuminated entry system. • LEFT SLIDING DOOR: Pressing the LEFT SLIDING DOOR BUTTON opens/closes the left power sliding door remotely. • RIGHT SLIDING DOOR: Pressing the RIGHT SLIDING DOOR BUTTON opens/closes the right power sliding door remotely. • LIFTGATE: Pressing the LIFTGATE BUTTON opens/closes the liftgate remotely, if equipped.If not equipped with power liftgate, pressing the liftgate button will allow a one time 30 second access to liftgate. • PANIC: Pressing the PANIC button sounds the horns at half second intervals, flashes the exterior lamps, and turns ON the interior lamps. The panic alarm will remain on for three minutes, or until the PANIC button is actuated again or the ignition switch is turned to the RUN position. The Remote Keyless Entry Module is capable of retaining the transmitter Vehicle Access Code(s) (VAC) in its memory even after vehicle power has been interrupted. NOTE: Additional features available to the customer are described in the Vehicle Owners Manual. The RKE system activates the optional memory seat, mirror system and adjustable pedals, if equipped. Two primary key fob transmitters can be programmed to actuate memory seat and mirror setting 1 or 2. Two additional key fob transmitters can be added, but they will not be able to operate the memory seat and mirror system (Refer to 8 - ELECTRICAL/POWER SEATS - OPERATION) and (Refer to 8 ELECTRICAL/POWER MIRRORS - OPERATION). DOOR CYLINDER LOCK SWITCH DESCRIPTION The Door Cylinder Lock Switch is used to: • Unlock/Lock all the doors via the Central Locking feature. • Arm/Disarm the Vehicle Theft Security System. • Trigger the Illuminated Entry feature. The door cylinder lock switch is mounted to the rear of the driver and passenger door lock cylinders. When installed on the rear of the cylinder, there is a tab on the lock cylinder that aligns with the switch to prevent it from turning. An anti-rotating device. The door cylinder lock switch is a one time use switch. Once it is removed from the rear of the door lock cylinder, it may not be reinstalled and a new switch must be used. OPERATION When the Door Cylinder Lock Switch is turned either way using the door key cylinder, the BCM reads a direct message signal from the switch, via the Programmable Communication Interface (PCI) bus. If turning the key cylinder once, toward the front of the vehicle (for either driver or passenger doors), this will: (1) Mechanically unlock the door lock. (2) Disarm the Vehicle Theft Security System (if equipped). (3) Turn on the Illuminated Entry (if equipped) for approximately 30 seconds. If the key cylinder is turned to the unlock position (toward the front of vehicle) twice within two seconds, all the doors and liftgate will unlock (if equipped with the central locking feature). To lock the vehicle using the door cylinder lock switch, turn the key cylinder toward the rear of the vehicle (either passenger or driver doors) once. This will lock the door that you are using the key on. If equipped with the central locking feature, this will lock all the other doors and liftgate. Furthermore, this will arm the vehicle theft security system and turn off the illuminated entry. DIAGNOSIS AND TESTING - DOOR CYLINDER LOCK SWITCH (1) Visually inspect the switch for proper installation. Make sure it is seated on the rear of the key cylinder, with the tab of the door key cylinder properly aligned with the slot on the door cylinder lock switch. (2) Disconnect the switch at the harness connector and check the resistance in each switch position. 8N - 42 POWER LOCKS RS DOOR CYLINDER LOCK SWITCH (Continued) CAUTION: Do not disconnect the switch from the rear of the door key cylinder. This switch is a one time use switch. Once it is removed from the rear of the switch, it is not reusable and must be replaced. Test the switch at the harness connector. DOOR CYLINDER LOCK SWITCH RESISTANCE SWITCH POSITION RESISTANCE VALUE COUNTERCLOCKWISE 5.4K OHMS NEUTRAL 18.4K OHMS CLOCKWISE 2K OHMS REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the door trim panel of the effected door cylinder lock switch (Refer to 23 - BODY/DOOR FRONT/TRIM PANEL - REMOVAL). (3) Close the door window. (4) Disconnect the door cylinder lock switch wire connector from the door harness, and wiring clip from the impact beam. (5) Remove the outer door handle from the door. (6) Remove the switch from the key cylinder in the door handle and remove from vehicle. INSTALLATION (1) Install the switch on the key cylinder in the door handle. (2) Install the door handle. (3) Connect the door cylinder lock switch wire connector to the door harness, and the wiring clip to the impact beam. (4) Install the door trim panel of the affected door cylinder lock switch (Refer to 23 - BODY/DOOR FRONT/TRIM PANEL - INSTALLATION). (5) Connect the battery negative cable. (6) Verify system operation. To test an individual door lock motor, disconnect the electrical connector from the motor. To lock the door, connect a 12 volt power source to the positive pin of the lock motor and a ground wire to the other pin. 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. To unlock the door reverse the wire connections at the motor pin terminals. If these results are NOT obtained, replace the motor. DOOR LOCK SWITCH DIAGNOSIS AND TESTING - DOOR LOCK SWITCH (1) Remove door trim panel. Refer to Body, Door Front, Trim Panel, Removal and Installation. (2) Disconnect wire connector from back of door lock switch. (3) Depress switch to LOCK position. (4) Using an ohmmeter, test switch resistance between Pins 2 and 3. Refer to the DOOR LOCK SWITCH CONTINUITY test and (Fig. 2). (5) Depress switch to UNLOCK position. (6) Test resistance between Pins 2 and 3. (7) Test resistance between pins 2 and 3 while switch is in its normal unactuated mode. (8) If resistance values are not within the parameters shown replace the door lock switch. DOOR LOCK MOTOR Fig. 2 DOOR LOCK SWITCH DIAGNOSIS AND TESTING - DOOR LOCK MOTOR Verify battery condition before testing door lock motor(s) (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - DIAGNOSIS AND TESTING). To determine which motor is faulty, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. In the event that none of the motors work, the problem may be caused by a shorted motor or a bad switch. Disconnecting the defective motor will allow the others to work. DOOR LOCK SWITCH CONTINUITY SWITCH POSITION CONTINUITY BETWEEN RESISTANCE VALUE LOCK 2 and 3 5.3K Ohm ± 5% UNLOCK 2 and 3 2.0K Ohm ± 5% UNACTUATED 2 and 3 18.3K Ohms ± 5% POWER LOCKS RS 8N - 43 DOOR LOCK SWITCH (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove door trim panel. Refer to Body, Door Front, Trim Panel, Removal. (3) Disconnect wire connector from back of door lock switch. (4) Remove two screws to door lock switch. (5) Remove switch from vehicle. age the rubber gasket during separation of the housing halves. INSTALLATION (1) Install the switch into the vehicle. (2) Install the two screws to door lock switch. (3) Connect wire connector to back of door lock switch. (4) Install door trim panel. Refer to Body, Door Front, Trim Panel, Installation. (5) Connect the battery negative cable. KEYLESS ENTRY TRANSMITTER STANDARD PROCEDURE STANDARD PROCEDURE - HORN CHIRP PREFERENCE DISABLING Fig. 3 RKE TRANSMITTER BATTERY REPLACEMENT - TYPICAL 1 - INSERT THIN COIN (2) Remove the battery from the transmitter back housing holder. (3) Replace the batteries. Avoid touching the new batteries with your fingers, Skin oils may cause battery deterioration. If you touch a battery, clean it off with rubbing alcohol. (4) To assemble the transmitter case, snap the two halves together. SPECIFICATIONS RANGE The horn chirp can be toggled using a DRB IIIt or by using the Remote Keyless Entry (RKE) transmitter. To DISABLE (cancelling) the horn chirp feature, press and hold the transmitter LOCK button for a minimum of five seconds. While pressing the LOCK button in, press the UNLOCK button. The horn chirp feature will not function until the above procedure is repeated. Normal operation range is up to a distance of 7 meters (23 ft.) of the vehicle. Range may be better or worse depending on the environment around the vehicle. Closeness to a radio frequency transmitter such as a radio station tower that is broadcasting on 105 MHz FM or a 156 MHz 2–way communication station, may degrade operational range, while range in an open field will be enhanced. ENABLING BATTERY The horn chirp can be toggled using a DRB IIIt or by using the Remote Keyless Entry (RKE) transmitter. To ENABLE (reinstate) the horn chirp feature, use any one of the four key fob transmitters and reverse the above procedures. It will ENABLE the horn chirp feature for all transmitters. STANDARD PROCEDURE - BATTERY REPLACEMENT (1) With the transmitter buttons facing down, use a coin (a penny is suggested) to pry the two halves of the transmitter apart (Fig. 3). Make sure not to dam- The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent, TWO cells are required. Battery life is about three years minimum. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean and dry. 8N - 44 POWER LOCKS REMOTE KEYLESS ENTRY MODULE DESCRIPTION The RKE module is capable of retaining up to four different Vehicle Access Codes. OPERATION Whenever the vehicle battery power is interrupted the RKE Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum 4) a DRB IIIt scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Refer to Electrical, Remote Keyless Entry Module, Standard Procedure - Programming RKE Module or the Proper Body Diagnostic Procedures manual. DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE 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. Refer to the proper Body Diagnostic Procedures Manual for testing the Remote Keyless Entry system using a DRB IIIt scan tool. Also refer to other interrelated systems groups within this manual: • Vehicle Theft Security System • Power Seats • Power Mirrors RS abbreviated chime to acknowledge that the programming of the transmitter has been completed and was successful. (7) Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). (8) Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the ignition OFF. A single chime will sound to verify that the RKE module will no longer accept additional Vehicle Access Code(s). (9) When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the two key fob transmitters that have been programmed to the memory seat and mirror system will operate it. If any key fob is replaced, the memory seat and mirror module will require programming. (Refer to 8 - ELECTRICAL/POWER SEATS DIAGNOSIS AND TESTING). REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove instrument panel top cover (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL TOP PAD - REMOVAL). (3) Remove screws holding RKE module to instrument panel. (4) Disconnect wire connector from RKE module (Fig. 4). STANDARD PROCEDURE - PROGRAMMING RKE MODULE (1) Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. (2) Insert ignition key into the ignition switch. (3) Turn the ignition switch to RUN position without starting engine. (4) Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum five seconds (maximum ten seconds). (5) While still holding UNLOCK button, and before ten seconds passes, press the PANIC button and release both at the same time. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). (6) Within 30 seconds of the chime, press and release the “LOCK” and “UNLOCK” buttons on the transmitter at the same time. Then press and release any one of the buttons. The BCM will sound an Fig. 4 RKE MODULE 1 - REMOTE KEYLESS ENTRY MODULE 2 - INSTRUMENT PANEL 3 - DEMISTER DUCT (5) Remove the RKE module from vehicle. POWER LOCKS RS 8N - 45 REMOTE KEYLESS ENTRY MODULE (Continued) INSTALLATION (1) Position the RKE module and install the screws. (2) Connect the wire connector to the RKE module (Fig. 4). (3) Install the instrument panel top pad. (4) Connect the battery negative cable. SLIDING DOOR LOCK MOTOR REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove sliding door trim panel (Refer to 23 BODY/DOORS - SLIDING/TRIM PANEL - REMOVAL). (3) Remove sound pad as necessary. (4) Remove latch/lock control cover. (5) Remove latch/lock control. (6) Remove screws holding door lock motor to latch/lock control (Fig. 5). (7) Remove lock motor from control. INSTALLATION (1) Position the lock motor on the latch/lock. (2) Install the screws retaining the motor to the latch/lock. (3) Install the latch/lock control. Fig. 5 SLIDING DOOR LOCK MOTOR 1 - SLIDING DOOR POWER LOCK MOTOR 2 - LATCH/LOCK CONTROL (4) Install the latch/lock control cover. (5) Install the sound pad and trim panel to the sliding door. 8N - 46 POWER MIRRORS RS POWER MIRRORS TABLE OF CONTENTS page POWER MIRRORS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . AUTOMATIC DAY / NIGHT MIRROR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - AUTOMATIC DAY / NIGHT MIRROR . . . . . . . . . . . . . . . . . . . . REMOTE SWITCH DIAGNOSIS AND TESTING - REMOTE SWITCH .......................... . . 46 . . 46 . . 46 . . 47 . . 47 . . 48 page REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . SIDEVIEW MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . POWER FOLDAWAY MIRROR SWITCH EXPORT DESCRIPTION . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 . . . . . . . . 49 . . . . . . . . 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 . 50 . 50 . 50 . . 49 POWER MIRRORS DESCRIPTION If equipped with power mirrors, the control switch is located on the instrument panel to the left of the headlamp switch. OPERATION The power mirrors are connected to battery feed at all times. Each mirror head contains two electric motors, two drive mechanisms, an electric heating element, and the mirror glass. If the vehicle is equipped with the optional memory system, each mirror head also contains both a horizontal and a vertical motor position sensor. One motor and drive controls mirror up-and-down movement, and the other controls right-and-left movement. An optional driver side outside electrochromic mirror is able to automatically change its reflectance level. This mirror is controlled by the circuitry of the automatic day/night inside rear view mirror. A thin layer of electrochromic material between two pieces of conductive glass make up the face of the mirror. Two photocell sensors on the inside rear view mirror are used to monitor light levels and adjust the reflectance of both the inside and driver side outside mirrors. This change in reflectance helps to reduce the glare of headlamps approaching the vehicle from the rear. (Refer to 8 - ELECTRICAL/POWER MIRRORS/ AUTOMATIC DAY / NIGHT MIRROR - DESCRIPTION) for more information on this system. The motors which operate the mirrors are part of the mirror assembly and cannot be serviced separately. DIAGNOSIS AND TESTING - POWER MIRRORS (1) Remove Power Mirror Switch. (Refer to 8 ELECTRICAL/POWER MIRRORS/POWER MIRROR SWITCH - REMOVAL). (2) Disconnect wiring harness connector to the power mirror switch and headlamp switch. (3) Using two jumper wires: • Connect one to a 12-volt source • Connect the other to a good body ground • Refer to the Mirror Test Chart for wire hookups at the switch connector (Fig. 1). POWER MIRRORS RS 8N - 47 POWER MIRRORS (Continued) Fig. 1 Power Mirror Connector POWER MIRROR MOTOR TEST SWITCH CONNECTOR 12 Volts Ground MIRROR REACTION Right Left PIN 12 PIN 6 — UP PIN 7 PIN 6 — LEFT PIN 6 PIN 12 — DOWN PIN 6 PIN 7 — RIGHT PIN 13 PIN 1 UP — PIN 8 PIN 1 LEFT — PIN 1 PIN 13 DOWN — PIN 1 PIN 8 RIGHT — PIN 5 PIN 11 LAMP LAMP (4) If results shown in table are not obtained, check for broken or shorted circuit, or replace mirror assembly as necessary. AUTOMATIC DAY / NIGHT MIRROR DESCRIPTION An automatic dimming inside day/night rear view mirror and an automatic dimming driver side outside rear view mirror are available factory-installed options on this model. Following is a general description of this optional equipment. The automatic day/night mirror is able to automatically change its reflectance. A thin layer of electrochromic material between two pieces of conductive glass make up the face of the mirror. Two photocell sensors are used to monitor light levels and adjust the reflectance of the mirror to reduce the glare of headlamps approaching the vehicle from the rear. For removal procedures, (Refer to 23 - BODY/INTERIOR/REAR VIEW MIRROR - REMOVAL). OPERATION The ambient photocell sensor faces forward, to detect the outside light levels. A second sensor faces rearward to detect the light level received through the vehicles back window. When the difference between the two light levels becomes too great (the light level received at the rear of the mirror is much higher than that at the front of the mirror), the mirror begins to darken. 8N - 48 POWER MIRRORS RS AUTOMATIC DAY / NIGHT MIRROR (Continued) The mirror switch allows the driver a manual control of whether the automatic dimming feature is operational. When AUTO is selected a small LightEmitting Diode (LED), to the right of the mirror switch, is illuminated. The automatic dimming feature will only operate when the ignition switch is in the On position. The mirror also senses the backup lamp circuit, and will automatically disable its selfdimming feature whenever the transmission gear selector is in the Reverse position. NOTE: The mirror always defaults to an ON state upon ignition. The driver side automatic dimming mirror is standard with the automatic dimming inside mirror. The signal to control the dimming of that mirror is generated by the automatic day/night inside rear view mirror circuitry. That signal is then delivered to the driver side outside rear view mirror on a hard wired circuit. The automatic day/night mirror cannot be repaired. If faulty or damaged, the entire inside rear view mirror assembly must be replaced. DIAGNOSIS AND TESTING - AUTOMATIC DAY / NIGHT MIRROR For circuit descriptions and diagrams, 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. (1) Check the fuse in the intelligent power module. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. (2) Turn the ignition switch to the On position. Check for battery voltage at the fuse in the intelligent power module. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. (3) Unplug the wire harness connector from the automatic day/night mirror. Check for battery voltage at the fused ignition switch output circuit cavity of the automatic day/night mirror wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required. (4) Turn the ignition switch to the Off position. Check for continuity between the ground circuit cavity of the automatic day/night mirror wire harness connector and a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the circuit to ground as required. (5) Turn the ignition switch to the On position. Set the parking brake. Place the transmission gear selector lever in the Reverse position. Check for battery voltage at the backup lamp switch output circuit cavity of the automatic day/night mirror wire harness connector. If voltage is present, reinstall the automatic day/night mirror wire harness connector and go to Step 6. If not OK, repair the open circuit as required. (6) Place the transmission gear selector lever in the Neutral position. Place the automatic day/night mirror switch in the On (LED in the switch is lighted) position. Cover the forward facing ambient photocell sensor to keep out any ambient light. NOTE: The ambient photocell sensor must be covered completely, so that no light reaches the sensor. Use a finger pressed tightly against the sensor, or cover the sensor completely with electrical tape. (7) Shine a light into the rearward facing headlamp photocell sensor. The automatic day/night mirror should darken. The automatic day/night mirror should darken within 2 minutes if testing for the first time. For immediate response, turn the vehicle OFF and back ON with the forward-facing light sensor still covered. This defeats the day-detect logic. If OK, go to Step 8. If not OK, replace the faulty mirror unit. (8) With the mirror darkened, place the transmission gear selector lever in the Reverse position. The automatic day/night mirror should return to its normal reflectance. If not OK, replace the faulty mirror unit. Bench testing both mirrors can be done, of care is exercised. For an inside mirror, the pin closest to he mount is 12V (+), the next is 12V (-). The third is reverse override. The fourth is outside mirror (+), and the fifth is outside mirror (-). Do not apply 12 volts to the fourth and fifth pins. With 12 volts on pins 1 and 2, the mirror can be tested by blocking the rear sensor and shining a light into the forward sensor. For an outside mirror, there is a 2–pin connector. Applying 1.2 volts will cause the mirror to dim. If the mirror does not dim, the entire glass assembly can be replaced just as it is when the glass is broken. WARNING: Do not apply 12 volts to the outside mirror. Damage to the mirror will result. POWER MIRRORS RS REMOTE SWITCH DIAGNOSIS AND TESTING - REMOTE SWITCH (1) Remove power mirror switch. (Refer to 8 ELECTRICAL/POWER MIRRORS/POWER MIRROR SWITCH - REMOVAL). (2) Disconnect wiring harness at switch connector. (3) Using a ohmmeter, test for continuity between the terminals of the switch (Fig. 2). Fig. 2 Mirror Switch MIRROR SWITCH TEST MIRROR SELECT SWITCH IN “LEFT” POSITION Move Button Continuity Between UP PIN 9 - PIN 12, PIN 6 - PIN 11, PIN 9 - PIN 13 LEFT PIN 9 - PIN 7, PIN 6 - PIN 11, PIN 9 - PIN 8 DOWN PIN 9 - PIN 6, PIN 12 - PIN 11, PIN 13 - PIN 11 RIGHT PIN 9 - PIN 6, PIN 7 - PIN 11, PIN 8 - PIN 11 MIRROR SELECT SWITCH IN “RIGHT” POSITION Move Button Continuity Between UP PIN 9 - PIN 13, PIN 1 - PIN 11, PIN 9 - PIN 12 LEFT PIN 9 - PIN 8, PIN 1 - PIN 11, PIN 9 - PIN 7 DOWN PIN 9 - PIN 1, PIN 13 - PIN 11, PIN 12 - PIN 11 RIGHT PIN 9 - PIN 1, PIN 8 - PIN 11, PIN 7 - PIN 11 LAMP PIN 5 - PIN 11 8N - 49 (4) If results shown in the table are not obtained, replace the switch. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove instrument panel lower cover. (3) From behind headlamp switch assembly, depress retaining tabs and push switch from instrument panel. (4) Disconnect wire connector from power mirror switch. (5) Disengage lock tabs above and below the mirror switch. (6) Remove power mirror switch from headlamp switch bezel. INSTALLATION (1) Install power mirror switch to the headlamp switch bezel. (2) Connect wire connector to the power mirror switch. (3) Insert headlamp switch assembly into instrument panel. (4) Install instrument panel lower cover. (5) Connect battery negative cable. SIDEVIEW MIRROR REMOVAL For service procedures, (Refer to 23 - BODY/EXTERIOR/SIDE VIEW MIRROR - REMOVAL). POWER FOLDAWAY MIRROR SWITCH - EXPORT DESCRIPTION These vehicles may be equipped with Power Foldaway Mirrors. This feature allows both the driver and passenger side view mirrors to fold inward (retract) on demand. The vehicle has an additional switch located on the steering column that controls the folding function of the mirror assembly (Fig. 3). The fold-away side view mirror is attached to the vehicle’s door in the same manner as mirrors without the fold-away option. The fold-away mirrors unique option is the internal motor which allows the mirrors to fold inward on demand. The fold-away mirror motor is not serviceable separately and if a motor is found to be faulty the entire side view mirror must be replaced. 8N - 50 POWER MIRRORS RS POWER FOLDAWAY MIRROR SWITCH - EXPORT (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the upper and lower steering column shroud (Refer to 19 - STEERING/COLUMN/LOWER SHROUD - REMOVAL). (3) Disconnect electrical harness connector. Fig. 3 POWER FOLDAWAY MIRROR SWITCH 1 - POWER FOLDAWAY MIRROR SWITCH 2 - STEERING COLUMN OPERATION When the mirror retract switch is depressed, both of the side view mirrors will fold inward, Thus making the overall width of the vehicle the smallest possible. This can be helpful were parking space is a absolute minimum. When the driver’s door is opened, only the driver’s door mirror will unfold. If the passenger door is opened, both mirrors will unfold. The power fold away mirror system consists of the following components: mirror switch, side view mirror, relay, wires and fuse. 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. Fig. 4 POWER FOLDING MIRROR SWITCH 1 - STEERING COLUMN SHROUD 2 - POWER FOLDAWAY SWITCH (4) Remove switch from steering column shroud (Fig. 4). INSTALLATION (1) Install switch to steering column shroud. (2) Connect wire harness connector. (3) Install the upper and lower steering column shroud (Refer to 19 - STEERING/COLUMN/LOWER SHROUD - INSTALLATION). (4) Connect the battery negative cable. POWER SEAT SYSTEM RS 8N - 51 POWER SEAT SYSTEM TABLE OF CONTENTS page POWER SEAT SYSTEM DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - MEMORY SYSTEM . . . . . OPERATION OPERATION - POWER SEAT SYSTEM . . . OPERATION - MEMORY SYSTEM . . . . . . . DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - POWER SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVER SEAT SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - DRIVER SEAT SWITCH .......................... REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . MEMORY SET SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - MEMORY SWITCH .......................... REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . PASSENGER SEAT SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 51 . . 52 . . 53 . . 53 . . 53 . . 54 . . 54 . . 55 . . 55 . . 55 . . 56 . . 56 . . 56 . . 57 . . 57 . . 57 page OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - PASSENGER SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . MEMORY MIRROR/SEAT MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - MEMORY MIRROR/SEAT MODULE . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . DRIVER POWER SEAT TRACK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - DRIVER POWER SEAT TRACK . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . PASSENGER POWER SEAT TRACK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - POWER SEAT TRACK ........................... REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57 . . 58 . . 58 . . 59 . . 59 . . 59 . . 59 . . 59 . . 59 . . 60 . . 60 . . 60 . . 61 . . 61 . . 61 . . 62 . . 62 . . 62 . . 63 . . 57 POWER SEAT SYSTEM that the power seats remain operational, regardless of the ignition switch position. DESCRIPTION WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS (Fig. 1). BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. DESCRIPTION The power seat system option allows the driver and front seat passenger to electrically adjust their seating positions for optimum control and comfort using the power seat switches located on the outboard seat cushion side shield of each front seat. Both power front seats can be adjusted in eight different directions up, down, front up, front down, rear up, rear down, forward, rearward and recliner forward and rearward. The power seat system receives battery current through a 40 amp fuse in the Intelligent Power Module and a 30 amp circuit breaker under the seat so A eight-way power seat is standard on highline models and optional on others. This option includes a eight-way adjustable seat cushion track and a twoway power seat back. 8N - 52 POWER SEAT SYSTEM RS POWER SEAT SYSTEM (Continued) DESCRIPTION - MEMORY SYSTEM Fig. 1 Identifying a Side Airbag Equipped Seat 1 - Airbag Label The eight-way power seat is also available with the heated seat and memory seat system that automatically positions the power seat for two different drivers. Refer to Heated Seats for more information on the heated seat option. Refer to Description Memory Seat System in this section for more information on the memory seat system. The power seat system includes the following components: • Power seat recliners • Power seat switches • Power seat tracks • Circuit breaker The power seat system with memory and heated seat options includes the following components: • Power seat recliner • Power seat switch • Power seat track. • Memory Seat Mirror Module (MSMM) • Memory set switch • Heated Seat Module (HSM) • Heated seat switch • Electronic Vehicle Information Center (EVIC) • Programmable Communications Interface (PCI) data bus network Refer to Wiring Diagrams for complete circuit diagrams. Following are general descriptions and operations for the major components in the power seat system and memory seat system. An electronic memory system is available on some models. The memory system is able to store and recall the driver side power seat positions (including the power recliner position) and both outside side view mirrors positions for two drivers. On vehicles equipped with a factory radio, the memory system is also able to store and recall radio station presets for two drivers. The memory system also will store and recall the last station listened to for each driver, even if it is not one of the preset stations. The memory system will automatically return to its preset settings when the corresponding numbered button of the memory switch is depressed, or when the doors are unlocked using the corresponding Remote Keyless Entry (RKE) transmitter. A customer programmable feature of the memory system allows the RKE recall of memory features to be disabled, if desired. This programmable feature is internal in the EVIC module, which is located in the overhead console. A Memory Seat Mirror Module (MSMM) is used on some models to control and integrate the many electronic functions and features included in the memory seat and mirror systems. The memory system includes the following components: • Memory Seat Mirror Module (MSMM) • Memory set switch • Position potentiometers on both outside side view mirrors • Position potentiometers on the driver side power seat track and power seat recliner motors. • Electronic Vehicle Information Center (EVIC) • Radio receiver (if PCI data bus capable). Certain functions of the memory system rely upon resources shared with other electronic modules in the vehicle over the Programmable Communications Interface (PCI) J1850 data bus network. The PCI data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, internal controller hardware, and component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Initial diagnosis of these electronic modules or the PCI data bus network requires the use of a DRB IIIt scan tool and the proper Diagnostic Procedures manual. If this method does not prove conclusive, the use of a automotive meter such as the Fluket, the proper wiring schematics and the service manual diagnostic routines are required. The other electronic modules that may affect memory system operation are as follows: RS POWER SEAT SYSTEM 8N - 53 POWER SEAT SYSTEM (Continued) • Body Control Module (BCM) - Refer to Body Control Module in Electronic Control Modules for more information. • Powertrain Control Module (PCM) - Refer to Powertrain Control Module in Electronic Control Modules for more information. Refer to Heated Seat System for more information on the heated seat system. Refer to Remote Keyless Entry System in Power Lock Systems for more information on the RKE system. Refer to Wiring Diagrams for complete circuit diagrams. Following are descriptions, theory of operation, diagnosis/testing procedures and removal/installation procedures of the major components in the memory and power seat systems. OPERATION OPERATION - POWER SEAT SYSTEM The power seat system receives battery current through fuse #22 in the Intelligent Power Module and a circuit breaker under the front seats, regardless of the ignition switch position. When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the appropriate power seat track adjuster motor. The selected adjuster motor operates to move the seat track through its drive unit in the selected direction until the switch is released, or until the travel limit of the seat track is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the seat track has reached its travel limit. The power seat track each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Refer to the owner’s manual in the vehicle glove box for more information on the features, use and operation of the power seat system. OPERATION - MEMORY SYSTEM The memory system receives battery current through fuse #22 in the Intelligent Power Module and the power seat system circuit breaker, located under each front seat near the rear edge of the seat cushion pans. The Memory Seat Mirror Module (MSMM) will drive a maximum of 2 motors at a time in a given direction. If conflicting directions are requested, the priority for response will be as follows: • Seat Track Rearward or Forward • Seat Front Down or Up • Seat Rear Down or Up • Recliner Rearward or Forward The inputs from these switches to the MSMM is a current limited battery source fed by the MSMM. This protects the MSMM printed circuit board traces from acting as fuses. All of these switch contact inputs to the MSMM are normally closed to ground, except when actuated. See the owner’s manual in the vehicle glove box for more information on the features, use and operation of the memory system. For diagnosis of the MSMM, the PCI data bus, or the other electronic modules on the PCI data bus that provide inputs and outputs for the memory system, the use of a DRBIIIt scan tool and the proper Diagnostic Procedures manual are recommended. ELECTRONIC VEHICLE INFORMATION CENTER The Electronic Vehicle Information Center (EVIC) serves as the user interface for the memory system. It displays memory system status messages and provides the user with the means for enabling and disabling the many customer programmable features available on the vehicle, including those for the memory system. See the owner’s manual in the vehicle glove box for more information on the features, use and operation of the EVIC. Refer to Electronic Vehicle Information Center in Overhead Console Systems for more information on the EVIC. DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - POWER SEAT SYSTEM Following are tests that will help to diagnose the hard wired components and circuits of the power seat system. However, if the vehicle is also equipped with the optional memory system, these tests may not prove conclusive in the diagnosis of the driver side power seat. In order to obtain conclusive testing of the driver side power seat with the memory system option, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to, or receive outputs from the memory system components must be checked. The most reliable, efficient, and accurate means to diagnose the driver side power seat with the memory system option requires the use of a DRB IIIt scan tool and the proper Diagnostic Procedures manual. The DRB IIIt scan tool can provide confirmation that the PCI data bus is functional, that all of the electronic modules are sending and receiving the proper messages on the PCI data bus, and that the memory 8N - 54 POWER SEAT SYSTEM RS POWER SEAT SYSTEM (Continued) system is receiving the proper hard wired inputs and relaying the proper hard wired outputs to perform its driver side power seat functions. WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. (1) If the driver power seat exhibits a interrupted or jerky motion, there is a possibility that the wires leading from the memory seat module to the memory seat motor are mis-wired. To check the concern, obtain a DRB IIIt scan tool and energize each axis one at a time. If any axis stops in approximately 2 seconds (without hitting the end of travel), the feedback for that axis may have an open, short or be miswired. Check the wiring to that axis (module to motor). Fix any wiring problems and retry that axis. (2) If any power seat is not operational in any direction, check the power seat circuit breaker, located under the trailing edge of the appropriate power seat. Refer to the Power Distribution section of this service manual for the circuit breaker diagnosis and testing procedure. (3) If the power seat circuit breaker is OK, check for proper 12v and ground connections at the power seat switch and/or memory seat module. Fix any wiring problems and retry. (4) Check the power seat system wire harness connections and pins to ensure proper circuit continuity and ground paths. For complete circuit diagrams, refer to Wiring Diagrams. (5) With the dome lamp on, apply the power seat switch in the direction of the failure. If the dome lamp dims, the seat may be jamming. Check under and behind the seat for binding or obstructions. If the dome lamp does not dim, proceed with testing of the individual components and circuits in the power seat system. DRB IIIt scan tool and the proper Diagnostic Procedures manual. The DRB IIIt scan tool can provide confirmation that the PCI data bus is functional, that all of the electronic modules are sending and receiving the proper messages on the PCI data bus, and that the memory system is receiving the proper hard wired inputs and relaying the proper hard wired outputs to perform its functions. (1) If the driver power seat exhibits a interrupted or jerky motion, there is a possibility that the wires leading from the memory seat module to the memory seat motor are mis-wired. To check the concern, obtain a DRB IIIt scan tool and energize each axis one at a time. If any axis stops in approximately 2 seconds (without hitting the end of travel), the feedback for that axis may have an open, short or be miswired. Check the wiring to that axis (module to motor). Fix any wiring problems and retry that axis. Refer to Wiring Diagrams for complete circuit schematic or connector pin-out information. DRIVER SEAT SWITCH DESCRIPTION Fig. 2 Power Seat Switch Location DIAGNOSIS AND TESTING - MEMORY SYSTEM In order to obtain conclusive testing of the memory system, the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to, or receive outputs from the memory system components must be checked. The most reliable, efficient, and accurate means to diagnose the memory system requires the use of a 1 - Power Seat Switch 2 - Seat Cushion Side Shield Vehicles equipped with power seats utilize a eightway power seat switch. This eight-way power seat switch features two knobs ganged together on the outboard seat cushion side shield (Fig. 2). POWER SEAT SYSTEM RS 8N - 55 DRIVER SEAT SWITCH (Continued) The switch is secured to the back of the seat cushion side shield with two screws. However, the control knobs for the seat switch unit must be removed before the seat switch can be removed from the side shield. The power seat switch cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. DRIVER SEAT SWITCH CONTINUITY TEST TABLE SWITCH POSITION DRIVER OFF PIN 5 & 4 PIN 5 & 3 PIN 5 & 2 PIN 5 & 10 PIN 5 & 9 PIN 5 & 8 PIN 5 & 7 PIN 5 & 6 FRONT RISER UP PIN 5 & 6 PIN 1 & 9 FRONT RISER DOWN PIN 5 & 9 PIN 1 & 6 CENTER SWITCH FORWARD PIN 5 & 3 PIN 1 & 10 CENTER SWITCH REARWARD PIN 5 & 10 PIN 3 & 1 REAR RISER UP PIN 5 & 7 PIN 1 & 8 REAR RISER DOWN PIN 5 & 8 PIN 1 & 7 RECLINER UP PIN 5 & 2 PIN 4 & 1 RECLINER DOWN PIN 5 & 4 PIN 2 & 1 OPERATION When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. See the owner’s manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. DIAGNOSIS AND TESTING - DRIVER SEAT SWITCH (1) Remove the power seat switch, refer to the Switch Removal and Installation procedures in this section. (2) Using an ohmmeter, check pin #1 of the power seat switch connector for continuity to ground. It should be present, If OK go to Step 3 , If NOT OK repair the open ground circuit as required. (3) Using an voltmeter, check pin #5 of the power seat switch connector for approx. 12v. It should be present, If OK go to Step 4 , If NOT OK repair the open voltage supply circuit as required. (4) Using an ohmmeter, verify the Seat Switch Continuity Test table, using the seat switch connector (Fig. 3). If there is no continuity at any of the switch positions, replace the power seat switch. CONTINUITY BETWEEN PINS REMOVAL Fig. 3 Seat Switch Pin Call-Out (1) Disconnect and isolate the battery negative cable. (2) On models equipped with the eight-way power seat, using a push pin remover or another suitable wide flat-bladed tool, gently pry the power seat and power recliner switch knobs off of the switch levers (Fig. 4). 8N - 56 POWER SEAT SYSTEM RS DRIVER SEAT SWITCH (Continued) MEMORY SET SWITCH DESCRIPTION Fig. 4 Removing Switch Control Knobs - Typical (3) Remove the screws that secure the outboard seat cushion side shield to the seat cushion frame. Refer to the Body section of the service manual for the procedure. (4) Pull the outboard seat cushion side shield away from the seat cushion frame far enough to access the power seat switch wire harness connector. (5) Disconnect the power seat wire harness connector from the power seat switch connector receptacle. (6) Remove the screws that secure the power seat switch to the inside of the outboard seat cushion side shield. (7) Remove the power seat switch from the outboard seat cushion side shield. INSTALLATION (1) Position the power seat switch onto the outboard seat cushion side shield. (2) Install and tighten the screws that secure the power seat switch to the inside of the outboard seat cushion side shield. Tighten the screws to 1.5 N·m (14 in. lbs.). (3) Reconnect the power seat wire harness connector to the power seat switch connector receptacle. (4) Position the outboard seat cushion side shield onto the seat cushion frame (5) Install and tighten the screws that secure the outboard seat cushion side shield to the seat cushion frame. Tighten the screws to 1.5 N·m (14 in. lbs.). (6) Install the switch knobs on the switch control levers, if equipped. (7) Reconnect the battery negative cable. Fig. 5 Memory Switch Location 1 - Memory Switch 2 - Switch Bezel Vehicles equipped with the memory system have a memory switch mounted to the driver side front door trim panel (Fig. 5). This switch is used to set and recall all of the memory system settings for up to two drivers. The memory switch is a resistor multiplexed unit that is hard wired to the Body Control Module (BCM). The BCM sends out the memory system set and recall requests to the other electronic modules over the Programmable Communications Interface (PCI) data bus. The memory switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. For complete circuit diagrams, refer to Wiring Diagrams. OPERATION The memory switch has three momentary switch buttons labeled Set, 1 and 2. The Driver 1 and Driver 2 buttons are back-lit with Light-Emitting Diodes (LED) for visibility. When the memory set switch is depressed, a resistance value is sent to the Body Control Module via hard wired connections. When the memory system is in “set” mode a chime will be generated by the body control module. POWER SEAT SYSTEM RS 8N - 57 MEMORY SET SWITCH (Continued) See the owner’s manual in the vehicle glove box for more information on the features, use and operation of the memory switch. DIAGNOSIS AND TESTING - MEMORY SWITCH (1) Remove the memory set switch from the drivers door panel (Refer to 8 - ELECTRICAL/POWER SEATS/MEMORY SET SWITCH - REMOVAL). (2) Using an ohmmeter, check for continuity on the memory select switch MUX circuit between the body control module C2 electrical connector and the memory switch connector. Continuity should be present, If OK go to Step 3, If NOT OK repair the open or shorted MUX circuit as required. (3) Using an ohmmeter, check for continuity on the memory select switch RETURN circuit between the body control module C2 electrical connector and the memory switch connector. Continuity should be present, If OK go to Step 4, If NOT OK repair the open or shorted RETURN circuit as required. (4) Using an ohmmeter, test the resistances of the memory switch in each switch position. See the Memory Switch Test Table. If OK, refer to Diagnosis and Testing Memory System in this section. If not OK, replace the faulty memory set switch. MEMORY SWITCH TEST TABLE MEMORY SWITCH POSITION RESISTANCE BETWEEN PINS RESISTANCE RANGE (OHMS) NEUTRAL 1&2 24650 ± 5% (24.65 k) MEMORY 1 1&2 6850 ± 5% (6.85 k) MEMORY 2 1&2 2100 ± 5% (2.10 k) SET 1&2 4490 ± 5% (4.49 k) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the front door trim panel switch bezel from the driver side front door. Using a thin flatbladed pry tool, gently pry the switch bezel away from the drivers door trim panel. (3) Disconnect the memory switch wire harness connector from the memory switch. (4) Remove the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. (5) Remove the memory switch. INSTALLATION (1) Position the memory switch and install and tighten the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. Tighten the screws to 2.2 N·m (20 in. lbs.). (2) Reconnect the memory switch wire harness connector to the memory switch. (3) Install the trim panel switch bezel onto the driver side front door. (4) Reconnect the battery negative cable. PASSENGER SEAT SWITCH DESCRIPTION Vehicles equipped with power seats utilize a tenway power seat switch. This ten-way power seat switch features two knobs ganged together on the outboard seat cushion side shield. The switch is secured to the back of the seat cushion side shield with two screws. However, the control knobs for the seat switch unit must be removed before the seat switch can be removed from the side shield. The power seat switch cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. OPERATION When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. See the owner’s manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. 8N - 58 POWER SEAT SYSTEM RS PASSENGER SEAT SWITCH (Continued) DIAGNOSIS AND TESTING - PASSENGER SEAT SWITCH (1) Remove the power seat switch, refer to the Switch Removal and Installation procedures in this section. (2) Using an ohmmeter, check pin #1 of the power seat switch connector for continuity to ground. It should be present, If OK go to Step 3 , If NOT OK repair the open ground circuit as required. (3) Using an voltmeter, check pin #5 of the power seat switch connector for approx. 12v. It should be present, If OK go to Step 4 , If NOT OK repair the open voltage supply circuit as required. (4) Using an ohmmeter, perform the Seat Switch Continuity Test table using (Fig. 6). If there is no continuity at any of the switch positions, replace the power seat switch. PASSENGER SEAT SWITCH CONTINUITY TEST TABLE SWITCH POSITION REMOVAL Fig. 6 Seat Switch Pin Call-Out (1) Disconnect and isolate the battery negative cable. (2) On models equipped with the eight-way power seat, using a push pin remover or another suitable wide flat-bladed tool, gently pry the power seat and power recliner switch knobs off of the switch levers (Fig. 7). CONTINUITY BETWEEN PINS PASSENGER OFF PIN 5 & 4 PIN 5 & 3 PIN 5 & 2 PIN 5 & 10 PIN 5 & 9 PIN 5 & 8 PIN 5 & 7 PIN 5 & 6 FRONT RISER UP PIN 5 & 9 PIN 1 & 6 FRONT RISER DOWN PIN 5 & 6 PIN 1 & 9 CENTER SWITCH FORWARD PIN 5 & 3 PIN 1 & 10 CENTER SWITCH REARWARD PIN 5 & 10 PIN 3 & 1 REAR RISER UP PIN 5 & 8 PIN 1 & 7 REAR RISER DOWN PIN 5 & 7 PIN 1 & 8 RECLINER UP PIN 5 & 2 PIN 4 & 1 RECLINER DOWN PIN 5 & 4 PIN 2 & 1 Fig. 7 Removing Switch Control Knobs - Typical (3) Remove the screws that secure the outboard seat cushion side shield to the seat cushion frame. Refer to the Body section of the service manual for the procedure. (4) Pull the outboard seat cushion side shield away from the seat cushion frame far enough to access the power seat switch wire harness connector. (5) Disconnect the power seat wire harness connector from the power seat switch connector receptacle. (6) Remove the screws that secure the power seat switch to the inside of the outboard seat cushion side shield. POWER SEAT SYSTEM RS 8N - 59 PASSENGER SEAT SWITCH (Continued) (7) Remove the power seat switch from the outboard seat cushion side shield. INSTALLATION (1) Position the power seat switch onto the outboard seat cushion side shield. (2) Install and tighten the screws that secure the power seat switch to the inside of the outboard seat cushion side shield. Tighten the screws to 1.5 N·m (14 in. lbs.). (3) Reconnect the power seat wire harness connector to the power seat switch connector receptacle. (4) Position the outboard seat cushion side shield onto the seat cushion frame (5) Install and tighten the screws that secure the outboard seat cushion side shield to the seat cushion frame. Tighten the screws to 1.5 N·m (14 in. lbs.). (6) Install the switch knobs on the switch control levers, if equipped. (7) Reconnect the battery negative cable. MEMORY MIRROR/SEAT MODULE DESCRIPTION Vehicles equipped with the memory mirror/seat option, utilize a memory module located under the drivers front seat. This module is basically wired inline between the power seat switch and the power seat track/adjuster motors, or in-line between the power mirror switch and the power side view mirror. The MSMM contains a central processing unit that communicates with other modules on the Programmable Communications Interface (PCI) data bus network. The Memory Seat/Mirror Module (MSMM) receives hard wired inputs from the driver power seat switch and the potentiometers on each of the driver side power seat track motors, or from the power mirror switch and the potentiometers on the side view mirror. The MSMM receives messages over the PCI data bus from the Body Control Module (BCM) (memory switch status), the Powertrain Control Module (PCM) (vehicle speed status). The MSMM will prevent the seat memory recall function from being initiated if the driver side seat belt is buckled, if the transmission gear selector lever is not in the Park or Neutral positions, or if the vehicle is moving. For diagnosis of the MSMM or the PCI data bus, a DRBIIIt scan tool and the proper Diagnostic Procedures manual are recommended. The MSMM cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Memory System in the Power Seat or Power Mirror section of this manual for more information on the memory system option. OPERATION When memory system operation is requested (depressing of the memory switch), a resistor multiplexed signal is sent from the memory switch to the body control module (BCM). The body control module will then send the appropriate signals out to the memory/mirror seat module, the memory/mirror seat module then applies the voltage supply to the power seat track or side-view mirror if the proper requirements are met. The vehicle speed must equal zero and the transmission must be in park or neutral in order for the memory system to function. DIAGNOSIS AND TESTING - MEMORY MIRROR/SEAT MODULE Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. If any of the above conditions are present, repair as necessary. If not, use a DRB IIIt scan tool and the proper Diagnostic Procedures Manual to test the memory/mirror seat module. For complete circuit diagrams, refer to Wiring Diagrams. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the driver side front bucket seat retaining nuts from under the vehicle (Refer to 23 BODY/SEATS/SEAT - REMOVAL). (3) Lift the drivers seat up and out of the mounting holes in the floor pan and lay the seat rearward to access the module located under the seat. It is not necessary to disconnect the seat electrical, just use care not to damage the wiring by over-extending. (4) Disconnect the memory/mirror seat module electrical connectors. Depress the retaining tab and pull straight apart. (5) Remove the module retaining bolts and remove the module from the bracket. INSTALLATION (1) Position and install the module retaining bolts. (2) Connect the memory/mirror seat module electrical connectors. (3) Position the drivers seat in the mounting holes in the floor pan. (4) Install the driver side front bucket seat retaining nuts from under the vehicle (Refer to 23 - BODY/ SEATS/SEAT - INSTALLATION). (5) Connect the battery negative cable. 8N - 60 POWER SEAT SYSTEM DRIVER POWER SEAT TRACK DESCRIPTION The eight-way power seat option includes a electrically operated power seat track located under each front seat. The left side power seat track also provides the mounting location for the body control module on this vehicle. The power seat circuit breakers are mounted on the rear of each power seat track, just behind the seat rear trim panel. The lower half of the power seat track is secured to the floor panel via four studs and nuts that must be accessed from the underside of the vehicle. Four bolts secure the bottom of the seat cushion pan to the upper half of the power seat track unit. Four additional bolts secure the seat back frame to the power seat track unit. The power seat track unit includes four reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. Each of the four power seat track motors used on models equipped with the optional memory system incorporates a position potentiometer integral to the motor assembly, which electronically monitors the motor position. This enables the memory system to function by referencing the motor positions programmed into the memory seat/mirror module. The front and rear of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward; or, they can be operated in unison by selecting the proper power seat switch functions, which will raise or lower the entire seat assembly. A third motor is the horizontal adjustment motor, which moves the seat track in the forward and rearward directions. The forth motor is the recliner adjustment motor, which moves the seat back in the forward and rearward directions. The power seat track unit cannot be repaired, and is serviced only as a complete unit. If any component in this unit is faulty or damaged, the entire power seat track unit must be replaced. OPERATION When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and RS ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. See the owner’s manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. DIAGNOSIS AND TESTING - DRIVER POWER SEAT TRACK WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Actuate the power seat switch to move all three power seat track adjusters in each direction. The power seat track adjusters should move in each of the selected directions. If a power seat track adjuster fails to operate in only one direction, move the adjuster a short distance in the opposite direction and test again to be certain that the adjuster is not at its travel limit. If the power seat track adjuster still fails to operate in only one direction, refer to Diagnosis and Testing Power Seat Switch in this section. If the power seat track adjuster fails to operate in more than one direction, perform the following tests. For complete circuit diagrams, refer to Wiring Diagrams. TESTING POWER SEAT TRACK MOTORS (1) Check the power seat circuit breaker under the seat. If OK, go to Step 2. If not OK, replace the faulty power seat circuit breaker. (2) Check for battery voltage at the power seat circuit breaker under the seat. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the fuse in the Intelligent Power Module as required. (3) Remove the outboard seat cushion side shield from the seat. Disconnect the seat wire harness connector from the power seat switch connector recepta- POWER SEAT SYSTEM RS 8N - 61 DRIVER POWER SEAT TRACK (Continued) cle. Check for battery voltage at the fused B(+) circuit cavity of the power seat wire harness connector for the power seat switch. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the power seat circuit breaker under the seat as required. (4) Check for continuity between the ground circuit cavity of the power seat wire harness connector for the power seat switch and a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open ground circuit to ground as required. (5) Test the power seat switch. Refer to Diagnosis and Testing Power Seat Switch in this section. If the switch tests OK, test the circuits of the power seat wire harness between the inoperative power seat track adjuster motor and the power seat switch for shorts or opens. If the circuits check OK, replace the faulty power seat track unit. If the circuits are not OK, repair the power seat wire harness as required. REMOVAL WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. (1) Remove the appropriate seat from the vehicle and place it on a clean work surface(Refer to 23 BODY/SEATS/SEAT - REMOVAL). (2) Remove the Body Control Module retaining screws. (3) Disconnect the body control module electrical connectors and remove the body control module from the power seat track. (4) Remove the rear fabric blocker trim panel from the rear of the front seat. (5) Remove the seat side cover and power seat switch as an assembly (Refer to 23 - BODY/SEATS/ SEAT CUSHION SIDE COVERS - REMOVAL). (6) Disconnect all electrical connectors connecting the power seat track to the seat assembly. (7) Pull the seat back trim cover up slightly to access and remove the two seat back frame mounting bolts and also remove two seat back recliner bolts. (8) Remove four seat track mounting bolts from the seat cushion pan. (9) Remove the power seat track from the seat. INSTALLATION (1) Position the seat cushion on the seat track. (2) Install the four seat track retaining bolts in the seat cushion pan. Torque the bolts to 28.5 N·m. (3) Position the seat back and install the two seat back frame mounting bolts and the two seat back recliner bolts. Torque the bolts to 55 N·m. (4) Route and connect the electrical connectors between the power seat track and the seat assembly. (5) Install the seat side cover and power seat switch as an assembly (Refer to 23 - BODY/SEATS/ SEAT CUSHION SIDE COVERS - INSTALLATION). (6) Install the rear fabric blocker trim panel on the rear of the front seat. (7) Position the body control module and connect the body control module electrical connectors. (8) Install the Body Control Module retaining screws. (9) Install the seat assembly in the vehicle (Refer to 23 - BODY/SEATS/SEAT - INSTALLATION). PASSENGER POWER SEAT TRACK DESCRIPTION The eight-way power seat option includes a electrically operated power seat track unit located under each front seat. The power seat circuit breaker is mounted on the rear of the power seat track, just behind the seat rear trim panel. The lower half of the power seat track is secured to the floor panel via four studs and nuts that must be accessed from the underside of the vehicle. Four bolts secure the bottom of the seat cushion frame to the upper half of the power seat track unit. Four additional bolts secure the seat back frame to the power seat track unit. The power seat track unit includes four reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. The front and rear of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward; or, they can be operated in unison by selecting the proper power seat switch functions, which will raise or lower the entire seat assembly. A third motor is the horizontal adjustment motor, which moves the seat track in the forward and rearward directions. The forth motor is the recliner adjustment motor, which moves the seat back in the forward and rearward directions. 8N - 62 POWER SEAT SYSTEM RS PASSENGER POWER SEAT TRACK (Continued) The power seat track unit cannot be repaired, and is serviced only as a complete unit. If any component in this unit is faulty or damaged, the entire power seat track unit must be replaced. OPERATION When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. See the owner’s manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. DIAGNOSIS AND TESTING - POWER SEAT TRACK WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Actuate the power seat switch to move all three power seat track adjusters in each direction. The power seat track adjusters should move in each of the selected directions. If a power seat track adjuster fails to operate in only one direction, move the adjuster a short distance in the opposite direction and test again to be certain that the adjuster is not at its travel limit. If the power seat track adjuster still fails to operate in only one direction, refer to Diagnosis and Testing Power Seat Switch in this section. If the power seat track adjuster fails to operate in more than one direction, perform the following tests. For complete circuit diagrams, refer to Wiring Diagrams. (1) Check the power seat circuit breaker under the seat. If OK, go to Step 2. If not OK, replace the faulty power seat circuit breaker. (2) Check for battery voltage at the power seat circuit breaker under the seat. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the fuse in the Intelligent Power Module as required. (3) Remove the outboard seat cushion side shield from the seat. Disconnect the seat wire harness connector from the power seat switch connector receptacle. Check for battery voltage at the fused B(+) circuit cavity of the power seat wire harness connector for the power seat switch. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the power seat circuit breaker under the seat as required. (4) Check for continuity between the ground circuit cavity of the power seat wire harness connector for the power seat switch and a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open ground circuit to ground as required. (5) Test the power seat switch. Refer to Diagnosis and Testing Power Seat Switch in this section. If the switch tests OK, test the circuits of the power seat wire harness between the inoperative power seat track adjuster motor and the power seat switch for shorts or opens. If the circuits check OK, replace the faulty power seat track unit. If the circuits are not OK, repair the power seat wire harness as required. REMOVAL WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. POWER SEAT SYSTEM RS 8N - 63 PASSENGER POWER SEAT TRACK (Continued) (1) Remove the appropriate seat from the vehicle (Refer to 23 - BODY/SEATS/SEAT - REMOVAL). (2) Remove the rear fabric blocker trim panel from the rear of the front seat. (3) Remove the seat side cover and power seat switch as an assembly (Refer to 23 - BODY/SEATS/ SEAT CUSHION SIDE COVERS - REMOVAL). (4) Disconnect all electrical connectors connecting the power seat track to the seat assembly. (5) Pull the seat back trim cover up slightly to access and remove the two seat back frame mounting bolts and seat back recliner bolts. (6) Remove four seat track mounting bolts from the seat cushion pan. (7) Remove the power seat track from the seat. INSTALLATION (1) Position the seat cushion on the seat track. (2) Install the four seat track retaining bolts in the seat cushion pan. Torque the bolts to 28.5 N·m. (3) Position the seat back and install the two seat back frame mounting bolts and the two seat back recliner bolts. Torque the bolts to 55 N·m. (4) Route and connect the electrical connectors between the power seat track and the seat assembly. (5) Install the seat side cover and power seat switch as an assembly (Refer to 23 - BODY/SEATS/ SEAT CUSHION - INSTALLATION). (6) Install the rear fabric blocker trim panel on the rear of the front seat. (7) Install the seat assembly in the vehicle (Refer to 23 - BODY/SEATS/SEAT - INSTALLATION). 8N - 64 POWER WINDOWS RS POWER WINDOWS TABLE OF CONTENTS page POWER WINDOWS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING - POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . VENT WINDOW MOTOR DIAGNOSIS AND TESTING - VENT WINDOW MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 . . . 64 . . . 64 . . . 65 . . . 65 POWER WINDOWS DESCRIPTION The Power Window System is activated through switches mounted on the driver and passenger door panels. OPERATION Front door window lift motors use permanent type magnets. The B+ and ground applied at the motor terminal pins will cause the motor to rotate in one direction. Reversing current through the motor terminals will cause the motor to rotate in the opposite direction. The power window motors ground through the master switch in the driver door by a black wire attached to the left cowl panel. 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. The power rear vent windows, if equipped, are operated by switches mounted in the driver door switch bezel. A separate switch is used for each window. Permanent magnet type motors connected to a crank system are used to open and close the rear vent windows. A battery positive and negative connection to either of the two motor terminals will cause the motor to rotate in one direction. Reversing current through these same two connections will cause the motor to rotate in the opposite direction. 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 page INSTALLATION . . . . . . . . . . . . . . . . . WINDOW MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . WINDOW SWITCH DIAGNOSIS AND TESTING - WINDOW SWITCH .................... REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65 . . . . . . . . 66 . . . . . . . . 66 . . . . . . . . 67 . . . . . . . . 67 information and location views for the various wire harness connectors, splices and grounds. DIAGNOSIS AND TESTING - POWER WINDOWS POWER WINDOW MOTOR TEST If the power window motor is receiving proper current and ground and does not operate, proceed with motor test. 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. (1) Remove front door trim panel and sound pad as necessary to gain access to power window motor wire connector, (Refer to 23 - BODY/DOOR - FRONT/ TRIM PANEL - REMOVAL). (2) Disconnect power window motor wire connector from door harness. (3) Using two jumper wires, connect one to a battery (+) source and the other to a good ground (-). (4) Connect the Negative (-) jumper probe to one of the motor connector terminals. (5) Momentarily touch the Positive (+) jumper probe to the other motor connector terminal. When positive probe is connected the motor should rotate in one direction to either move window up or down. If window is all the way up or down the motor will grunt and the inner door panel will flex when actuated in that one direction. (6) Reverse jumper probes at the motor connector terminals and window should now move in opposite direction. If window does not move or grunt, replace the motor. POWER WINDOWS RS 8N - 65 POWER WINDOWS (Continued) If window moved completely up or down, reverse the jumper probes and cycle window to the opposite position to verify full operation. If motor grunts and does not move, verify that regulator is not binding. WIRING VOLTAGE TEST The following wiring test determines whether or not voltage is continuous through the body harness to switch. (1) Remove the power window switch and bezel assembly from the driver door. (Refer to 8 - ELECTRICAL/POWER WINDOWS/POWER WINDOW SWITCH - REMOVAL). (2) Disconnect wire connector from back of power window switch. (3) Switch ignition ON position. (4) Connect the clip end of a 12 volt test light to Pin 13 in door harness connector at the window switch. Touch the test light probe to Pin 9 and then to Pin 11. • If the test light illuminates, the wiring circuit between the battery and switch is OK. • If the lamp does not illuminate, first check the 25 amp circuit breaker attached to the electrical distribution wiring bracket. If the circuit breaker is OK, then check the 40 amp fuse (#28) in the Integrated Power Module (IPM). If both components are OK, then check for a broken wire. • 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 pinout information and location views for the various wire harness connectors, splices and grounds. VENT WINDOW MOTOR DIAGNOSIS AND TESTING - VENT WINDOW MOTOR If the power vent window motor is receiving proper current and ground and does not operate proceed with motor test. 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. (1) Remove D-pillar trim panel necessary to gain access to power vent window motor wire connector, (Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL - REMOVAL) or (Refer to 23 - BODY/ INTERIOR/RIGHT D-PILLAR TRIM PANEL REMOVAL). (2) Disconnect power vent window motor wire connector from body harness. (3) Using two jumper wires, connect one to a battery (+) source and the other to a good ground (-). (4) Connect the Negative (-) jumper probe to one of the motor connector terminals. (5) Momentarily touch the Positive (+) jumper probe to the other motor connector terminal. When positive probe is connected the motor should rotate in one direction to either move window open or closed. If window is all the way open or closed the motor will grunt and the crank system will flex when actuated in that one direction. Reverse jumper probes at the motor connector terminals and window should now move in opposite direction. If window does not move or grunt, replace the motor. If window moved completely open or closed, reverse the jumper probes and cycle window to the opposite position to verify full operation. If motor grunts and does not move, verify that crank system is not binding. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove D-pillar trim panel. (Refer to 23 BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL REMOVAL) or (Refer to 23 - BODY/INTERIOR/ RIGHT D-PILLAR TRIM PANEL - REMOVAL). (3) Disconnect wire connector from power vent motor. (4) Using a flat bladed tool, carefully lift the circular actuator link tab. Remove link from window ball socket. (5) Remove bolts holding power vent motor to D-pillar (Fig. 1). (6) Remove power vent motor. INSTALLATION (1) Obtain new vent window motor. (2) Snap the actuator link socket onto the quarter window ball socket. Using a soft rubber mallet, push the circular link tab flush with link surface. (3) Install bolts holding power vent motor to D-pillar. (4) Reconnect wire connector to power vent motor. (5) Reconnect the battery negative cable. (6) Cycle quarter window open/close to verify function. (7) Install D-pillar trim panel. 8N - 66 POWER WINDOWS RS VENT WINDOW MOTOR (Continued) POWER WINDOW MASTER SWITCH TEST SWITCH POSITION CONTINUITY BETWEEN OFF 13 and 1 13 and 2 13 and 3 13 and 4 13 and 5 13 and 6 13 and 7 13 and 8 Fig. 1 VENT WINDOW MOTOR 1 2 3 4 - VENT WINDOW MOTOR WIRE HARNESS CONNECTOR BOLT VENT WINDOW WINDOW MOTOR REMOVAL The window motor is incorporated into the window regulator assembly. If the window motor requires replacement, the window regulator must be replaced. (Refer to 23 - BODY/DOOR - FRONT/WINDOW REGULATOR - REMOVAL). WINDOW SWITCH UP DRIVER 11 and 8 *DOWN DRIVER 11 and 6 *X DOWN DRIVER 11and 6 UP PASSENGER 9 and 4 DOWN PASSENGER 9 and 2 LEFT VENT OPEN 11 and 7 LEFT VENT CLOSE 9 and 3 RIGHT VENT OPEN 9 and 1 RIGHT VENT CLOSE 11 and 5 * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 (3) If the result are not OK, replace the driver side window lift switch. (4) Test passenger door switch for continuity as described in (Fig. 3). DIAGNOSIS AND TESTING - WINDOW SWITCH (1) Remove the desired switch to be tested from the door trim panel. Driver’s side (master) or passenger side. (Refer to 8 - ELECTRICAL/POWER WINDOWS/POWER WINDOW SWITCH - REMOVAL). (2) Using an ohmmeter, Test driver door switch for continuity as described in (Fig. 2). Fig. 2 Power Window Master Switch Connector Fig. 3 Passenger Door Power Window Switch POWER WINDOWS RS 8N - 67 WINDOW SWITCH (Continued) PASSENGER WINDOW SWITCH TEST SWITCH POSITION CONTINUITY BETWEEN OFF 3 AND 8 OFF 2 AND 5 UP 1 AND 8 DOWN 1 AND 5 (5) If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down circuit senses stall current (window has reached end of down travel), the switch will turn current off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. If the electronic circuit in the switch fails to detect a stall current, the auto down circuit will time out within 9 to 13 seconds. REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Using a trim stick, start at the bottom of the switch and bezel assembly and pry up to remove the switch and bezel assembly from the door trim panel (Fig. 4). Fig. 4 POWER WINDOW SWITCH 1 - DOOR TRIM PANEL 2 - POWER WINDOW SWITCH AND BEZEL ASSEMBLY (3) Unlatch the locking tab on the harness side connector of the switch. (4) Disconnect wire harness connectors from switch. INSTALLATION (1) Reconnect wire harness connector to switch. (2) Insert switch into door trim panel and press into place. (3) Reconnect battery negative cable.